Establishing cycle times in a high variety manufacturing environment using DMAIC Procedure

Chikez, Hory Bakand (2016-12)

Thesis (MEng)--Stellenbosch University, 2016.

Thesis

ENGLISH ABSTRACT: Today many competitive manufacturing companies use a variety of quantitative metrics to provide them with the means to track and identify problems with performance, and to make good decisions. This explains the need for a weaving and dyeing plant based in Cape Town, South Africa, to establish production performance metrics in general, and the cycle times at various workstations in particular. Also, this research assumes that the establishment of the cycle times at various workstations of the weaving and dyeing plant constitutes an important step toward the adequate management of the manufacturing lead times. While there exist many generic techniques for establishing the cycle times in a manufacturing environment, there is limited literature on how to establish the cycle times in a high variety production environment, such as a weaving and dyeing plant. Consequently, this research focuses on establishing cycle times at various workstations of a weaving and dyeing plant, while taking into account the entire population of products that has to be produced at each workstation. Furthermore, following the establishment of the cycle times, this research creates a cycle time control sheet to be used by the weaving and dyeing department’s managers, in order to better control the manufacturing lead times. Lastly this research identifies the DMAIC procedure as a viable quality management approach, which can be used to realign the weaving and dyeing production performance measurements with the requirements of its ISO 9001:2008 certification. Therefore DMAIC is used as the most suitable technique for carrying out this research.

AFRIKAANSE OPSOMMING: In vandag se mededingende vervaardiging omgewing maak maatskappye gebruik van ‘n verskeidenheid van kwantitatiewe statistieke om probleem situasies te identifiseer en op te volg met die doel om beter besluitnemings tegnieke toe te pas. Dit verklaar die behoefte hoekom ‘n weef en kleur vervaardiger in Kaapstad, Suid Afrika, om produksie prestasie metings in die algemeen te bepaal asook om siklus tye by elke werkstasie te bestudeer. Hierdie navorsing aanvaar dat die siklus tye metings by elke werkstasie ‘n waardevolle stap is in die proses om van die weef en kleur vervaardiger suksesvol te bestuur ten opsigte van vervaardiging lewertye. Baie generiese tegnieke bestaan alreeds om die siklus tye in die vervaardigings omgewing vas te stel, maar daar is 'n beperkte literatuur hieroor in 'n hoë verskeidenheid produksie-omgewing, soos 'n weef en kleur vervaardiger. Gevolglik gaan hierdie navorsing fokus op die vestiging van siklus tye op verskillende werkstasies, met inagneming van die totale verskeidenheid van produkte wat geproduseer word by elke werkstasie. Nadat die siklus tye vasgevang is, gaan die navorsing voort om 'n siklus tyd kontroleblad te skep vir die gebruik van bestuurders in die weef en kleur afdeling ten einde 'n beter beheer oor die produksie lewertye te hê. Laastens identifiseer hierdie navorsing die proses DMAIC as 'n lewensvatbare gehalte bestuursbenadering wat gebruik kan word in die weef en kleur produksie omgewing omdat dit aan die prestasiemaatstawwe vereistes van die ISO 9001: 2008 sertifisering voldoen. Dus is hierdie die rede hoekom DMAIC gebruik gaan word as die mees geskikte tegniek vir die uitvoering van hierdie navorsing.

Please refer to this item in SUNScholar by using the following persistent URL: http://hdl.handle.net/10019.1/100140
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