Managing changeover waste in manufacturing plants when using single minute exchange of dies
- Authors: Madhav, Rushil
- Date: 2016
- Subjects: Lean manufacturing , Production management , Industrial management , Process control
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/213270 , uj:21127
- Description: Abstract: The research aimed to determine how single minute exchange of dies (SMED) is implemented in practice when considering the critical success factors (CSFs) of lean. It also aimed to determine what effect these factors had on waste generated within changeover processes and the possible savings that could be generated when considering these factors during the implementation of SMED. Six case studies across two production lines were conducted in order to investigate the importance and the impact of considering the CSFs of lean when implementing SMED in an organization. It helped determine that the CSFs of lean form a part of SMED’s implementation process and its prerequisites. The consideration and presence of the CSFs are critical and the analysis conducted between the two production lines indicated that these factors influence the implementation process of SMED. These factors also have a direct impact on the waste and helped manage the levels of wastes, which in turn reduced the costs of changeovers. It provided practical guidelines that integrated the soft and technical areas to achieve a fully integrated management and manufacturing system that resulted in efficient changeover processes. The result ultimately provides organizations with the required flexibility to satisfy customers as changeovers can take place more frequently with better quality, reasonable delivery periods, affordable rates, smaller lot/batch sizes and lower inventory levels. , M.Ing. (Engineering Management)
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- Authors: Madhav, Rushil
- Date: 2016
- Subjects: Lean manufacturing , Production management , Industrial management , Process control
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/213270 , uj:21127
- Description: Abstract: The research aimed to determine how single minute exchange of dies (SMED) is implemented in practice when considering the critical success factors (CSFs) of lean. It also aimed to determine what effect these factors had on waste generated within changeover processes and the possible savings that could be generated when considering these factors during the implementation of SMED. Six case studies across two production lines were conducted in order to investigate the importance and the impact of considering the CSFs of lean when implementing SMED in an organization. It helped determine that the CSFs of lean form a part of SMED’s implementation process and its prerequisites. The consideration and presence of the CSFs are critical and the analysis conducted between the two production lines indicated that these factors influence the implementation process of SMED. These factors also have a direct impact on the waste and helped manage the levels of wastes, which in turn reduced the costs of changeovers. It provided practical guidelines that integrated the soft and technical areas to achieve a fully integrated management and manufacturing system that resulted in efficient changeover processes. The result ultimately provides organizations with the required flexibility to satisfy customers as changeovers can take place more frequently with better quality, reasonable delivery periods, affordable rates, smaller lot/batch sizes and lower inventory levels. , M.Ing. (Engineering Management)
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Automated mine optimization system for diamond mines
- Authors: Pan, Xiaowei
- Date: 2013
- Subjects: Process optimization , Process control , Soft sensor , Smart sensor , Diamond mines and mining
- Type: Article
- Identifier: uj:4733 , ISSN 2277 – 4378 , http://hdl.handle.net/10210/11559
- Description: A diamond mine generally consists of mining and mineral beneficiation operations. Mining operation includes planning, drilling, explosion, loading; hauling and mineral processing normally has the following operations: crushing; screening; washing; transporting; separation; sorting; storing; water treatment, etc. The operation could be described as a complex and expensive balancing act where material flow rates, size, density and other factors must all be in required balance if any degree of plant optimization and efficiency is to be achieved. One of the main objectives to optimally operate a mine is to maintain balanced production among all product streams. To achieve a balanced and optimal production at a mine, two tasks at least must be considered. The first is to have an optimal production plan, including a set of optimal production targets for all process units. And the second task is to make sure that all those optimal targets in the mentioned optimal production plan must be achieved at all process units by using all resources available. To achieve the mentioned two tasks, all measurements, equipment and systems at the mine must be available in real time, particularly those critical measurements such as weightometers, densitometers, ore types; stockpile levels. With the advancement and applications of technologies in mineral processing industry, an automated mine optimization system is developed to include the following three functions: (1) mine production optimizer; (2) various dynamic controllers; and (3) a set of soft sensors. Over the past ten years, a large amount of work has been done to develop the system, started from forming the concept to testing and implementation at various mines. The system can potentially help improve the production throughput up to 30% at the mineral processing operation of a mine.
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- Authors: Pan, Xiaowei
- Date: 2013
- Subjects: Process optimization , Process control , Soft sensor , Smart sensor , Diamond mines and mining
- Type: Article
- Identifier: uj:4733 , ISSN 2277 – 4378 , http://hdl.handle.net/10210/11559
- Description: A diamond mine generally consists of mining and mineral beneficiation operations. Mining operation includes planning, drilling, explosion, loading; hauling and mineral processing normally has the following operations: crushing; screening; washing; transporting; separation; sorting; storing; water treatment, etc. The operation could be described as a complex and expensive balancing act where material flow rates, size, density and other factors must all be in required balance if any degree of plant optimization and efficiency is to be achieved. One of the main objectives to optimally operate a mine is to maintain balanced production among all product streams. To achieve a balanced and optimal production at a mine, two tasks at least must be considered. The first is to have an optimal production plan, including a set of optimal production targets for all process units. And the second task is to make sure that all those optimal targets in the mentioned optimal production plan must be achieved at all process units by using all resources available. To achieve the mentioned two tasks, all measurements, equipment and systems at the mine must be available in real time, particularly those critical measurements such as weightometers, densitometers, ore types; stockpile levels. With the advancement and applications of technologies in mineral processing industry, an automated mine optimization system is developed to include the following three functions: (1) mine production optimizer; (2) various dynamic controllers; and (3) a set of soft sensors. Over the past ten years, a large amount of work has been done to develop the system, started from forming the concept to testing and implementation at various mines. The system can potentially help improve the production throughput up to 30% at the mineral processing operation of a mine.
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Design and implementation of a supervisory expert system for hot rolling process optimisation
- Authors: Jordaan, Albertus Laing
- Date: 2009-02-26T12:20:29Z
- Subjects: Expert systems (Computer science) , Process control , Stainless steel industry
- Type: Mini-Dissertation
- Identifier: http://ujcontent.uj.ac.za8080/10210/367454 , uj:8162 , http://hdl.handle.net/10210/2168
- Description: M.Ing. , This dissertation stresses the need and value of adding an Artificial Intelligence level between manufacturing units and First Principle Models that supply processing set points. The value is proven by evaluating the effect of designing and implementing a supervisory expert system for hot rolling process optimisation at Columbus Stainless Ltd. Pty. The hot rolling mill’s mainly fuzzy logic artificial intelligence “Expert System” functions as an extra diagnostic and control system that manages the performance of the processing set point models. The Expert System was developed in order to effectively imitate what the human experts used to do – which was to virtually continuously optimise the rolling process by making database data changes. The human experts had to make these process adjustments in order to compensate for the unavoidable imperfections and shortcomings of First Principle Models, which are unable to perfectly model nature. Even though the Expert System addresses a vast amount of hot rolling product quality and throughput control aspects, it still sufficiently automates human expert control to successfully manage production performance in all areas of control. This document was written in a format that would comply with Masters Degree Dissertation standards, while providing a document that can easily be used by Columbus Stainless personnel as a reference book of the philosophies, strategies and design of the Expert System.
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- Authors: Jordaan, Albertus Laing
- Date: 2009-02-26T12:20:29Z
- Subjects: Expert systems (Computer science) , Process control , Stainless steel industry
- Type: Mini-Dissertation
- Identifier: http://ujcontent.uj.ac.za8080/10210/367454 , uj:8162 , http://hdl.handle.net/10210/2168
- Description: M.Ing. , This dissertation stresses the need and value of adding an Artificial Intelligence level between manufacturing units and First Principle Models that supply processing set points. The value is proven by evaluating the effect of designing and implementing a supervisory expert system for hot rolling process optimisation at Columbus Stainless Ltd. Pty. The hot rolling mill’s mainly fuzzy logic artificial intelligence “Expert System” functions as an extra diagnostic and control system that manages the performance of the processing set point models. The Expert System was developed in order to effectively imitate what the human experts used to do – which was to virtually continuously optimise the rolling process by making database data changes. The human experts had to make these process adjustments in order to compensate for the unavoidable imperfections and shortcomings of First Principle Models, which are unable to perfectly model nature. Even though the Expert System addresses a vast amount of hot rolling product quality and throughput control aspects, it still sufficiently automates human expert control to successfully manage production performance in all areas of control. This document was written in a format that would comply with Masters Degree Dissertation standards, while providing a document that can easily be used by Columbus Stainless personnel as a reference book of the philosophies, strategies and design of the Expert System.
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A proposed integration of process control and strategic management in an industrial organisation
- Authors: Cronje, Jacobus Christiaan
- Date: 2012-08-15
- Subjects: Strategic planning , Process control
- Type: Thesis
- Identifier: uj:9321 , http://hdl.handle.net/10210/5761
- Description: M.Comm. , The value of Strategic Management in organisation has been realised all across the world. Strategic Management theory has been proven on all levels of organisation from corporate, through organisational and also functional areas. It is not uncommon for organisation to have well-published and effective functional strategies, such as financial, marketing and human resources. Strategy however in the engineering functions of organisations is often neglected or even non-existent. Process Automation is one of these functional areas, which is extremely seldom strategised. This study aims at addressing these shortcomings, by firstly recognising the change world economy, which illustrate the volatility of the modern economy. The study then attempt to prove that in order to have a competitive advantage, is it necessary to establish and implement a strategic plan. The chapter illustrates that operational effectiveness is a function of strategic planning but not in itself a competitive advantage. The study continues at evaluating different sources of strategic management to supply insight and background into the strategic management area. The second part of the study moves away from commercial items and address the field of process control and automation. It illustrates the scope and importance of process automation for all modern industries. Once strategic management and process automation has been adequately discussed, it is necessary to derive the Process Automation Strategy through combining the two very different fields of study. It is important to consider Process Automation Strategy not as an isolated subject field, but an integrated part of the organisation. For this reason was all influences considered on the organisation. A theoretical guideline to the establishment of a Process Automation Strategy was derived through the Strategic Management procedure discussed earlier in the study.
- Full Text:
- Authors: Cronje, Jacobus Christiaan
- Date: 2012-08-15
- Subjects: Strategic planning , Process control
- Type: Thesis
- Identifier: uj:9321 , http://hdl.handle.net/10210/5761
- Description: M.Comm. , The value of Strategic Management in organisation has been realised all across the world. Strategic Management theory has been proven on all levels of organisation from corporate, through organisational and also functional areas. It is not uncommon for organisation to have well-published and effective functional strategies, such as financial, marketing and human resources. Strategy however in the engineering functions of organisations is often neglected or even non-existent. Process Automation is one of these functional areas, which is extremely seldom strategised. This study aims at addressing these shortcomings, by firstly recognising the change world economy, which illustrate the volatility of the modern economy. The study then attempt to prove that in order to have a competitive advantage, is it necessary to establish and implement a strategic plan. The chapter illustrates that operational effectiveness is a function of strategic planning but not in itself a competitive advantage. The study continues at evaluating different sources of strategic management to supply insight and background into the strategic management area. The second part of the study moves away from commercial items and address the field of process control and automation. It illustrates the scope and importance of process automation for all modern industries. Once strategic management and process automation has been adequately discussed, it is necessary to derive the Process Automation Strategy through combining the two very different fields of study. It is important to consider Process Automation Strategy not as an isolated subject field, but an integrated part of the organisation. For this reason was all influences considered on the organisation. A theoretical guideline to the establishment of a Process Automation Strategy was derived through the Strategic Management procedure discussed earlier in the study.
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The influence of an ERP system on the value chain process of multinational enterprises (MNEs)
- Authors: Bosombo, Folo-Ralph.
- Date: 2012-06-08
- Subjects: Manufacturing resource planning. , Process control , Business enterprises Computer networks. , Information technology Management.
- Type: Mini-Dissertation
- Identifier: uj:8756 , http://hdl.handle.net/10210/5107
- Description: M.B.A. , The study set out to assess the influence of enterprise resource planning (ERP) system software on the value chain process of multinational enterprises (MNEs). This was achieved through the literature review that addressed the relation between the value chain approach as a strategic tool and ERP system theory. The ERP system is positioned as a total solution for the MNE, and it contains the best business practices that are derived from the various generic business functions of the value chain architecture and configuration. A set of research hypotheses was developed, which were tested in accordance with the research methodology and the design issues for the qualitative study. The different chapters evolved along with a case study of an ERP system, namely Axapta software. For the quantitative study, preliminary interviews were conducted to select the MNEs that use SAP software. Thereafter a self-administered survey was applied relating to the strategy and the value chain integration through the ERP system to the MNE's ERP system users. The research results in the qualitative study show that for ERP software to integrate the MNE's functional activities and processes in the value chain system globally and effectively, it has to position itself as a value chain system with e-business mechanisms. In addition it has to suit the global ERP characteristics as an information interchange, sharing and service. It has to be a flexible and comprehensive, modular, open, integrated and multifunctional system, with an option to customisation in selecting modules that best suit the MNE's management to craft its business's activities. The above was proved through the analyses of Axapta software attributes by means of a technical strategic planning tool, namely the value chain approaches, and the strategic supply chain factors for ERP software evaluation. Axapta software met the requirements of a general and global ERP system model and it is indeed a value chain system. The following statement can be cited as the most important findings of the qualitative study: For the MNE to derive value from ERP system integration and utilisation, the strategic information technology (IT) plan has to be formulated and followed in order to measure the beneficial cost and efficiency of implementing the ERP system, and to assess the suitability of ERP software during the selection process in accordance with the MNE's objectives that will facilitate the success of ERP implementation usage. ERP software adopted for the MNE has to include the international architecture and configuration types that align with the MNE’s strategy and Internet application. This must include all the necessary value chain functional modules relating to the ERP system as an integrating tool that will influence the MNE to align its strategy to gain competitive advantage. Consequently, such an ERP system will allow the MNE to strengthen and integrate all its applications and activities in the value chain system. As a result the different organisational suppliers and partners must be linked with the MNE's value chain system to enhance the operational sites' users to operate efficiently, more reliably and in co-ordination with the MNE. The necessary information and data must be available across the entire organisation's system from the trading partners to the customers so that they can be satisfied on with the necessary urgency. In the statistical analysis conducted from the self-administered survey, the major finding is the positive view of the employers and employees of the customisation of ERP, i.e. SAP software, which helps MNEs to craft the software according to their objectives and with the use of a strategic IT plan. In conclusion the study highlighted the inseparability of ERP system theory from the value chain approaches. Therefore, the study came to position ERP system theoretically as an evaluative tool and technically as a value chain system that becomes an evaluative tool for ERP software activities assessment. Moreover the study pointed out the importance of the use of a strategic IT plan within the MNE. However, the main contribution and value of this study is obviously to assist any MNE in the process of migrating business systems. The methodical approach facilitates the selection and the evaluation of ERP software requirements within an organisation, which can meet its growth targets and objectives. Thus, the strategic supply chain factors for ERP software evaluation and the application of the value chain approaches discussed in this study will contribute to the acquisition of fit and compatible ERP software. The choice of the right ERP software will definitely allow MNEs to derive the benefits of the ERP system across its entire value chain sites (nationally and internationally). It can be concluded from this study that any organisation wanting to invest in ERP system implementation must apply the methodical approach formulated in this study by the researcher. It is recommended that the assessment of an ERP system's modular and functional activities, together with the organisation's value chain activities, be given priority before the acquisition and adoption of the ERP system.
- Full Text:
- Authors: Bosombo, Folo-Ralph.
- Date: 2012-06-08
- Subjects: Manufacturing resource planning. , Process control , Business enterprises Computer networks. , Information technology Management.
- Type: Mini-Dissertation
- Identifier: uj:8756 , http://hdl.handle.net/10210/5107
- Description: M.B.A. , The study set out to assess the influence of enterprise resource planning (ERP) system software on the value chain process of multinational enterprises (MNEs). This was achieved through the literature review that addressed the relation between the value chain approach as a strategic tool and ERP system theory. The ERP system is positioned as a total solution for the MNE, and it contains the best business practices that are derived from the various generic business functions of the value chain architecture and configuration. A set of research hypotheses was developed, which were tested in accordance with the research methodology and the design issues for the qualitative study. The different chapters evolved along with a case study of an ERP system, namely Axapta software. For the quantitative study, preliminary interviews were conducted to select the MNEs that use SAP software. Thereafter a self-administered survey was applied relating to the strategy and the value chain integration through the ERP system to the MNE's ERP system users. The research results in the qualitative study show that for ERP software to integrate the MNE's functional activities and processes in the value chain system globally and effectively, it has to position itself as a value chain system with e-business mechanisms. In addition it has to suit the global ERP characteristics as an information interchange, sharing and service. It has to be a flexible and comprehensive, modular, open, integrated and multifunctional system, with an option to customisation in selecting modules that best suit the MNE's management to craft its business's activities. The above was proved through the analyses of Axapta software attributes by means of a technical strategic planning tool, namely the value chain approaches, and the strategic supply chain factors for ERP software evaluation. Axapta software met the requirements of a general and global ERP system model and it is indeed a value chain system. The following statement can be cited as the most important findings of the qualitative study: For the MNE to derive value from ERP system integration and utilisation, the strategic information technology (IT) plan has to be formulated and followed in order to measure the beneficial cost and efficiency of implementing the ERP system, and to assess the suitability of ERP software during the selection process in accordance with the MNE's objectives that will facilitate the success of ERP implementation usage. ERP software adopted for the MNE has to include the international architecture and configuration types that align with the MNE’s strategy and Internet application. This must include all the necessary value chain functional modules relating to the ERP system as an integrating tool that will influence the MNE to align its strategy to gain competitive advantage. Consequently, such an ERP system will allow the MNE to strengthen and integrate all its applications and activities in the value chain system. As a result the different organisational suppliers and partners must be linked with the MNE's value chain system to enhance the operational sites' users to operate efficiently, more reliably and in co-ordination with the MNE. The necessary information and data must be available across the entire organisation's system from the trading partners to the customers so that they can be satisfied on with the necessary urgency. In the statistical analysis conducted from the self-administered survey, the major finding is the positive view of the employers and employees of the customisation of ERP, i.e. SAP software, which helps MNEs to craft the software according to their objectives and with the use of a strategic IT plan. In conclusion the study highlighted the inseparability of ERP system theory from the value chain approaches. Therefore, the study came to position ERP system theoretically as an evaluative tool and technically as a value chain system that becomes an evaluative tool for ERP software activities assessment. Moreover the study pointed out the importance of the use of a strategic IT plan within the MNE. However, the main contribution and value of this study is obviously to assist any MNE in the process of migrating business systems. The methodical approach facilitates the selection and the evaluation of ERP software requirements within an organisation, which can meet its growth targets and objectives. Thus, the strategic supply chain factors for ERP software evaluation and the application of the value chain approaches discussed in this study will contribute to the acquisition of fit and compatible ERP software. The choice of the right ERP software will definitely allow MNEs to derive the benefits of the ERP system across its entire value chain sites (nationally and internationally). It can be concluded from this study that any organisation wanting to invest in ERP system implementation must apply the methodical approach formulated in this study by the researcher. It is recommended that the assessment of an ERP system's modular and functional activities, together with the organisation's value chain activities, be given priority before the acquisition and adoption of the ERP system.
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A proposed framework for the consideration of advanced process control pre-deployment factors
- Authors: Mpahlwa, Lita Lunga
- Date: 2019
- Subjects: Process control , Engineering - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/293882 , uj:31964
- Description: M.Phil. (Engineering Management) , Abstract: This research is intended for process control practitioners, plant decision-makers and process control enthusiasts who are considering implementing advanced process control (APC). An understanding of APC is developed from an introductory level; a definition is provided, as well as a discussion of its purpose and how it relates to process control. Three types of APC are examined to illustrate the capabilities and applications of APC techniques. The applicability of the selected APC technologies is investigated based on the type of manufacturing industry. This investigation is conducted because there are varying approaches to the implementation of APC technologies, irrespective of manufacturing industry. The various industries are explored to gain an understanding of the inconsistencies in the APC selection approach and to test the proposed facilitation framework. The researcher proposes a facilitation process that would guide the decision-making process that ranks the anticipated risks. The risks would need to be addressed for the selected APC technique to contribute positively to the profitability of the enterprise. Hypothetical scenarios are defined to test the facilitation process and to validate its appropriateness. The results are consistent with prior research pertaining to the scenarios defined. A process that considers both qualitative and quantitative factors in strategic decision making, for the best APC technique, is described. This study did not consider the in-depth technical nature of each advanced control technique and its applicability to each industry. It is not an application model that can be exposed to all manufacturing sectors without considering the dynamics of process control.
- Full Text:
- Authors: Mpahlwa, Lita Lunga
- Date: 2019
- Subjects: Process control , Engineering - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/293882 , uj:31964
- Description: M.Phil. (Engineering Management) , Abstract: This research is intended for process control practitioners, plant decision-makers and process control enthusiasts who are considering implementing advanced process control (APC). An understanding of APC is developed from an introductory level; a definition is provided, as well as a discussion of its purpose and how it relates to process control. Three types of APC are examined to illustrate the capabilities and applications of APC techniques. The applicability of the selected APC technologies is investigated based on the type of manufacturing industry. This investigation is conducted because there are varying approaches to the implementation of APC technologies, irrespective of manufacturing industry. The various industries are explored to gain an understanding of the inconsistencies in the APC selection approach and to test the proposed facilitation framework. The researcher proposes a facilitation process that would guide the decision-making process that ranks the anticipated risks. The risks would need to be addressed for the selected APC technique to contribute positively to the profitability of the enterprise. Hypothetical scenarios are defined to test the facilitation process and to validate its appropriateness. The results are consistent with prior research pertaining to the scenarios defined. A process that considers both qualitative and quantitative factors in strategic decision making, for the best APC technique, is described. This study did not consider the in-depth technical nature of each advanced control technique and its applicability to each industry. It is not an application model that can be exposed to all manufacturing sectors without considering the dynamics of process control.
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