The quest for process operations variability reduction in manufacturing firms in South Africa

Katombe, Madi; Munapo, Elias

doi:10.17159/2222-3436/2016/v19n3a10

Cited by 2 publications

(3 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Taneja and Manchanda (2013) highlighted the main aim in the interactions between the entities and system components is to enable a comprehensive analysis of their impact on the outcomes of these engagements. To achieve optimum improvement levels, these entities take advantage of the availability of variability analysis and control mechanisms through the continuous improvement of the processes that maintain the operations necessary for business and productivity to continue (Katombe and Manupo, 2016). According to Phiri and Chen (2014), the issue of design for sustainability is a vital consideration because of the influence that such an approach has effective operations in cross-industrial applications.…”

Section: Introductionmentioning

confidence: 99%

Integration of Six Sigma and simulations in real production factory to improve performance – a case study analysis

Ahmed

Olsen²,

Page³

2022

IJLSS

View full text Add to dashboard Cite

Purpose The overarching objective of this research is to integrate the Lean Six Sigma (LSS) framework with computer simulation to improve the production efficiency of a light-emitting diode (LED) manufacturing factory. Design/methodology/approach Recently, the idea of taking advantage of the benefits of Six Sigma and simulation models together has led both industry and the academy towards further investigation and implementation of these methodologies. From this perspective, the present research will illustrate the effectiveness of using LSS methodology in a real factory environment by using the combination of three simulation methods which are system dynamics (SD), discrete-event simulation (DES) and agent-based (AB) modelling. Findings The hybrid simulation method applied in this research was found to accurately mimic and model the existing real factory environment. The define, measure, analyse, control and improve (DMAIC)-based improvements showed that the applied method is able to improve machine utilization rates while balancing the workload. Moreover, queue lengths for several stations were shortened, and the average processing time was decreased by around 50%. Also, a weekly production increase of 25% was achieved while lowering the cost per unit by around 8%. Research limitations/implications While the case study used was for a LED manufacturing system, the proposed framework could be implemented for any other existing production system. The research also meticulously presents the steps carried out for the development of the multi-method simulation model to allow readers to replicate the model and tailor it for their own case studies and projects. The hybrid model enables managers to navigate the trade-off decisions they often face when choosing advanced production output ahead of continuous improvement practices. The adoption of methodologies outlined in this paper would attain improvements in terms of queue lengths, utilization, reduced costs and improved quality and efficiency of a real, small factory. The findings suggest improvements and create awareness among practitioners for the utilization of quality tools that will provide direct benefits to their companies. Although the multi-method simulation is effective, a limitation of the current study is the lack of micro details within each station. Furthermore, the results are all based on one specific case study which is not enough to suggest and generalized findings. Originality/value This research combines the use of the three main hybrid simulation paradigms (SD, DES and AB) in a unified framework DMAIC methodology. Choosing the right models in DMAIC is important, challenging and urgently necessary. Also, this paper shows empirical evidence on its effectiveness.

show abstract

Section: Introductionmentioning

confidence: 99%

Integration of Six Sigma and simulations in real production factory to improve performance – a case study analysis

Ahmed

Olsen²,

Page³

2022

IJLSS

View full text Add to dashboard Cite

show abstract

“…However, Hopp and Spearman [20] opined that in reducing expected waiting time, the plant managers either must reduce process time (also called cycle time) or reduce variability by pooling resources. Pathway analysis was a model proposed by Katombe and Munapo [21]. Although from literature, the techniques have a lot in common, they are also uniquely different in their applications.…”

Section: Introductionmentioning

confidence: 99%

“…For brevity, the consulted relevant literature is further discussed in tabular format, Table 1, after classification according to keywords of the title. Article cited [1], [4], [21] [9], [11], [14], [17], [20] [6], [7], [8], [10], [12], [14], [15], [23] [13], [22], [24], [25], [26] [16], [17] Problem purpose…”

Section: Introductionmentioning

confidence: 99%

Balancing a multistage vehicle number plate production line using effective cycle time model

Nwanya¹,

Achebe²

2020

j. sist. manaj. ind.

View full text Add to dashboard Cite

Shortest product cycle time is a key criterion for job sequencing and measuring competitiveness among entrepreneurial-based firms. Now, the long waiting time of job orders constitutes a deterministic production line problem in vehicle number plate production plants in Nigeria. Case studies were conducted on those plants, confidentially identified in this paper as A, B, C, and D. Delays caused by non-value-adding work processes are major culprits among other contributors to the long queues at these plants. The value stream mapping technique was applied to identify non-value adding activities before the production line was balanced using an effective cycle time model. The index cases to a balanced line, as shown in the results, are increases in process rate by 41 %, 59 %, 42 %, and 71 % for A, B, C, and D, respectively, and overall line efficiency. Next, the system capacities correspondingly increased with the elimination of wastages. These increments imply that bottleneck activities have been minimized, and we have a balanced production line. The devised solution procedure is reliable and recommended to other line manufacturing concerns that experience delays and bottleneck problems.

show abstract

The quest for process operations variability reduction in manufacturing firms in South Africa

Cited by 2 publications

References 29 publications

Integration of Six Sigma and simulations in real production factory to improve performance – a case study analysis

Integration of Six Sigma and simulations in real production factory to improve performance – a case study analysis

Balancing a multistage vehicle number plate production line using effective cycle time model

Contact Info

Product

Resources

About