Converting activities to processes for operational efficency improvement of a South African agricultural equipment manufacturer

Abstract

South African agricultural equipment manufacturers face increasing pressures from global competition, in response they have resorted to manufacturing customised machinery in a bid to secure market share. This strategy, while successful, introduces a high degree of product variation and complexity - increasing strain on the manufacturing operation. In response to these strains, manufacturers are placing emphasis on finding new ways to improve manufacturing costs and accelerate product delivery. The objective of this dissertation is to assemble and sequence a practical framework, using commonly available (and established) tools and improvement methodologies, which will allow its user to effectively direct process oriented improvement through analysis and modification of the operations at the activity level. The framework seeks to achieve this by formalising the operating structures already present and subsequently modifying it, in a value driven manner, using lean principles and heuristic methods for the purposes of providing practical, easily integrate-able and affordable solutions aimed at promoting operational excellence while eliminating Lean wastages. Testing conducted showed that regardless of environment lean principles can be successfully adapted to produce significant reductions in lead time and gains in both product flow and overall quality.