An investigation into the main causes for poor OEE at the Struandale Engine Plant of Ford Motor Company of Southern Africa
- Authors: Koen, Peter-John
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Industrial equipment
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8672 , http://hdl.handle.net/10948/1172 , Total productive maintenance -- South Africa , Industrial equipment
- Description: The Struandale Engine Plant (SEP) was set up in 1924 and was the 16th Ford plant outside North America. The plant has since produced a variety of different components ranging from wheel hubs, to engine components such as crank shafts and cylinder blocks, to the assembly of engines. Manufacturing at this plant has predominantly been via the job-shop method, where mass production techniques were used. The RoCam programme preparation started in 1999. In 2001, SEP experienced a very steep ramp-up due to an unexpected surge in volume requirements. This forced the plant’s Human Resources team to embark on an “emergency” recruitment drive to cover the required human resources to support the programme. Due to this action being taken by the Human Resources department, the educational level of the employees was at a very basic level and had an adverse effect on productivity. The SEP operating committee made a decision in 2004 to focus on the implementation and maintenance of the Ford Production System (FPS). This initiative was important because ageing equipment needed to be maintained at predetermined intervals through continuous improvement techniques that form part of the FPS programme. If these techniques are not in place, the Overall Equipment Efficiency (OEE) suffers. This programme comprises a number of critical elements such as FTPM that requires a certain education and skill level in effort to completely comprehend the system. Evidently, education was an issue and an effort had to be made to upgrade the workforce skill’s level, specifically the team leaders. On the 30th January 2008, Ford Motor Company of Southern Africa (FMCSA) had announced plans to invest more than R1.5-billion to expand its operations in South Africa for the production of Ford's next-generation compact pick-up truck iv and Puma diesel engine. In an effort to secure and retain the Puma contract at SEP, the plant had to prove that it could compete globally; hence it had to improve OEE levels to the world-class standard. The Puma engine contract had been contracted to South America, Turkey, Thailand, and South Africa. This was a strategic move in order to retain flexibility within the supply chain i.e. if one supplier / plant cannot deliver, demand can be shifted to one of three alternative suppliers. The problem statement which will be addressed by this research is: What are the main causes for the poor Overall Equipment Efficiency level (OEE) at the Struandale Engine Plant of Ford Motor Company of Southern Africa? The Primary Objective of this research is to: Identify the main causes for the poor Overall Equipment Efficiency level (OEE) at the Struandale Engine Plant of Ford Motor Company of Southern Africa
- Full Text:
- Date Issued: 2009
- Authors: Koen, Peter-John
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Industrial equipment
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8672 , http://hdl.handle.net/10948/1172 , Total productive maintenance -- South Africa , Industrial equipment
- Description: The Struandale Engine Plant (SEP) was set up in 1924 and was the 16th Ford plant outside North America. The plant has since produced a variety of different components ranging from wheel hubs, to engine components such as crank shafts and cylinder blocks, to the assembly of engines. Manufacturing at this plant has predominantly been via the job-shop method, where mass production techniques were used. The RoCam programme preparation started in 1999. In 2001, SEP experienced a very steep ramp-up due to an unexpected surge in volume requirements. This forced the plant’s Human Resources team to embark on an “emergency” recruitment drive to cover the required human resources to support the programme. Due to this action being taken by the Human Resources department, the educational level of the employees was at a very basic level and had an adverse effect on productivity. The SEP operating committee made a decision in 2004 to focus on the implementation and maintenance of the Ford Production System (FPS). This initiative was important because ageing equipment needed to be maintained at predetermined intervals through continuous improvement techniques that form part of the FPS programme. If these techniques are not in place, the Overall Equipment Efficiency (OEE) suffers. This programme comprises a number of critical elements such as FTPM that requires a certain education and skill level in effort to completely comprehend the system. Evidently, education was an issue and an effort had to be made to upgrade the workforce skill’s level, specifically the team leaders. On the 30th January 2008, Ford Motor Company of Southern Africa (FMCSA) had announced plans to invest more than R1.5-billion to expand its operations in South Africa for the production of Ford's next-generation compact pick-up truck iv and Puma diesel engine. In an effort to secure and retain the Puma contract at SEP, the plant had to prove that it could compete globally; hence it had to improve OEE levels to the world-class standard. The Puma engine contract had been contracted to South America, Turkey, Thailand, and South Africa. This was a strategic move in order to retain flexibility within the supply chain i.e. if one supplier / plant cannot deliver, demand can be shifted to one of three alternative suppliers. The problem statement which will be addressed by this research is: What are the main causes for the poor Overall Equipment Efficiency level (OEE) at the Struandale Engine Plant of Ford Motor Company of Southern Africa? The Primary Objective of this research is to: Identify the main causes for the poor Overall Equipment Efficiency level (OEE) at the Struandale Engine Plant of Ford Motor Company of Southern Africa
- Full Text:
- Date Issued: 2009
Evaluating the success of total productive maintenance at Faurecia interior systems
- Faber, John Cornelius Jacobus
- Authors: Faber, John Cornelius Jacobus
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Total quality management -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8670 , http://hdl.handle.net/10948/1206 , Total productive maintenance -- South Africa , Total quality management -- South Africa
- Description: Manufacturing processes should operate at optimal levels in order to remain competitive in current economic environment. The optimal manufacturing performance can be achieved by overall equipment efficiency which is also a measurement for Total Productive Maintenance (TPM). The successful implementation of TPM has been evaluated at Faurecia Interior Systems. The research consisted out of a literature review into the elements and benefits of TPM. A questionnaire was sent to all operator level personnel at Faurecia Interior Systems to establish their views on the implementation level of TPM at the East London site. In conclusion, this research paper has also led to the development of recommendations which should improve TPM at the site.
- Full Text:
- Date Issued: 2009
- Authors: Faber, John Cornelius Jacobus
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Total quality management -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8670 , http://hdl.handle.net/10948/1206 , Total productive maintenance -- South Africa , Total quality management -- South Africa
- Description: Manufacturing processes should operate at optimal levels in order to remain competitive in current economic environment. The optimal manufacturing performance can be achieved by overall equipment efficiency which is also a measurement for Total Productive Maintenance (TPM). The successful implementation of TPM has been evaluated at Faurecia Interior Systems. The research consisted out of a literature review into the elements and benefits of TPM. A questionnaire was sent to all operator level personnel at Faurecia Interior Systems to establish their views on the implementation level of TPM at the East London site. In conclusion, this research paper has also led to the development of recommendations which should improve TPM at the site.
- Full Text:
- Date Issued: 2009
The factors that hinder the overall equipment effectiveness at Ford Struandale Engine Plant
- Authors: Qweleka, Sazile
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Industrial equipment -- Maintenance and repair -- Planning , Plant maintenance -- Management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8673 , http://hdl.handle.net/10948/1163 , Total productive maintenance -- South Africa , Industrial equipment -- Maintenance and repair -- Planning , Plant maintenance -- Management
- Description: This treatise investigates the underlying factors that are hindering the improvement of Overall Equipment Effectiveness at the Ford Struandale Engine Plant. In January of 2008 the Ford Motor Company announced plans to invest more than R1.5 billion to expand operations for the production of Ford's next-generation compact pickup truck and the PUMA diesel engine. Ford will use the investment to expand operations both in Silverton for the production of 75 000 units of a new bakkie and in Port Elizabeth for 220 000 units of its new-generation PUMA diesel engines (http://www.autoblog.com /2008/01/31/ford-to-invest-209m-in-south-africa-for-new-ranger-pickup/). Only five Ford plants globally will be producing the PUMA engine (Turkey, UK, Thailand, Argentina and South Africa – Ford Struandale Engine Plant). The Ford Struandale Engine Plant will be the only plant which will have the I4 assembly, I5 assembly and 3C (Crank, Cylinder Block, and Cylinder Head) machining and the expectations of operating in a lean environment is high. The management team at the Ford Struandale Engine Plant needs to understand what the underlying factors that are hindering the improvement of Overall Equipment Effectiveness of the plant or, in other words, they need to be informed of the total benefits of TPM. A literature review was conducted to determine what the theory reveals about Overall Equipment Effectiveness, the three factors of OEE (Availability, Performance Efficiency, and Quality), the influence of Six Big Losses on each of the factors and the role of Total Productive Maintenance in improving OEE by eliminating these Six Big Losses. A Ford literature study was conducted to reveal the current literature being applied at Ford. This was then followed by an empirical survey conducted within the Ford Struandale Engine Plant. In addition, a task team formed to analyse the current maintenance operating strategy. Finally, the findings from discussions with the task team, the empirical survey, Ford Struandale Engine Plant literature survey and a general literature survey were amalgamated to draw conclusions relating to the Ford Struandale Engine Plant. These conclusions indicate what the underlying factors are that are hindering the improvement of Overall Equipment Effectiveness of the Ford Struandale Engine Plant facilities and equipment. Then recommendations are made as to how the Ford Struandale Engine Plant can improve the Overall Equipment Effectiveness of its facilities and equipment.
- Full Text:
- Date Issued: 2009
- Authors: Qweleka, Sazile
- Date: 2009
- Subjects: Total productive maintenance -- South Africa , Industrial equipment -- Maintenance and repair -- Planning , Plant maintenance -- Management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8673 , http://hdl.handle.net/10948/1163 , Total productive maintenance -- South Africa , Industrial equipment -- Maintenance and repair -- Planning , Plant maintenance -- Management
- Description: This treatise investigates the underlying factors that are hindering the improvement of Overall Equipment Effectiveness at the Ford Struandale Engine Plant. In January of 2008 the Ford Motor Company announced plans to invest more than R1.5 billion to expand operations for the production of Ford's next-generation compact pickup truck and the PUMA diesel engine. Ford will use the investment to expand operations both in Silverton for the production of 75 000 units of a new bakkie and in Port Elizabeth for 220 000 units of its new-generation PUMA diesel engines (http://www.autoblog.com /2008/01/31/ford-to-invest-209m-in-south-africa-for-new-ranger-pickup/). Only five Ford plants globally will be producing the PUMA engine (Turkey, UK, Thailand, Argentina and South Africa – Ford Struandale Engine Plant). The Ford Struandale Engine Plant will be the only plant which will have the I4 assembly, I5 assembly and 3C (Crank, Cylinder Block, and Cylinder Head) machining and the expectations of operating in a lean environment is high. The management team at the Ford Struandale Engine Plant needs to understand what the underlying factors that are hindering the improvement of Overall Equipment Effectiveness of the plant or, in other words, they need to be informed of the total benefits of TPM. A literature review was conducted to determine what the theory reveals about Overall Equipment Effectiveness, the three factors of OEE (Availability, Performance Efficiency, and Quality), the influence of Six Big Losses on each of the factors and the role of Total Productive Maintenance in improving OEE by eliminating these Six Big Losses. A Ford literature study was conducted to reveal the current literature being applied at Ford. This was then followed by an empirical survey conducted within the Ford Struandale Engine Plant. In addition, a task team formed to analyse the current maintenance operating strategy. Finally, the findings from discussions with the task team, the empirical survey, Ford Struandale Engine Plant literature survey and a general literature survey were amalgamated to draw conclusions relating to the Ford Struandale Engine Plant. These conclusions indicate what the underlying factors are that are hindering the improvement of Overall Equipment Effectiveness of the Ford Struandale Engine Plant facilities and equipment. Then recommendations are made as to how the Ford Struandale Engine Plant can improve the Overall Equipment Effectiveness of its facilities and equipment.
- Full Text:
- Date Issued: 2009
The impact of the absence of a total productive maintenance (TPM) program at a plastic painting plant
- Authors: Hempel, Calvern Anthony
- Date: 2007
- Subjects: Plant maintenance -- Management , Total productive maintenance -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8590 , http://hdl.handle.net/10948/524 , Plant maintenance -- Management , Total productive maintenance -- South Africa
- Description: This research was concerned with investigating “the absence of Total Productive Maintenance (TPM)” at a plastic painting plant. TPM is a combination of operations and maintenance activities and is performed by operators under their own authority and is called “autonomous maintenances”. The author has tested the degree of implementation of TPM by using a sevenstep TPM implementation model this highlighted an absence of TPM in the organisation investigated. TPM is a relatively new concept in the South African automotive industry and has not been fully accepted by management as a solution to the maintenance problems in the organisation. Due to a long implementation period and the difficulty in measuring the benefits of the TPM program for the organisation TPM tends not to be implemented by companies. The research studies several maintenance philosophies each with its own advantages and disadvantages. The benefits that arise from the implementation of an effective TPM philosophy were explored. The development of an effective improved model for the implementation of TPM was investigated. Maintenance engineers and managers in any organisation can use this model to implement an effective TPM program. The seven-step TPM implementation model formed the basis for the compilation of a questionnaire. A survey was conducted to determine if an absence of TPM existed in a plastic painting plant. The results from the survey were drawn up and recommendations to further develop a model for the implementation of TPM was put forward.
- Full Text:
- Date Issued: 2007
- Authors: Hempel, Calvern Anthony
- Date: 2007
- Subjects: Plant maintenance -- Management , Total productive maintenance -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8590 , http://hdl.handle.net/10948/524 , Plant maintenance -- Management , Total productive maintenance -- South Africa
- Description: This research was concerned with investigating “the absence of Total Productive Maintenance (TPM)” at a plastic painting plant. TPM is a combination of operations and maintenance activities and is performed by operators under their own authority and is called “autonomous maintenances”. The author has tested the degree of implementation of TPM by using a sevenstep TPM implementation model this highlighted an absence of TPM in the organisation investigated. TPM is a relatively new concept in the South African automotive industry and has not been fully accepted by management as a solution to the maintenance problems in the organisation. Due to a long implementation period and the difficulty in measuring the benefits of the TPM program for the organisation TPM tends not to be implemented by companies. The research studies several maintenance philosophies each with its own advantages and disadvantages. The benefits that arise from the implementation of an effective TPM philosophy were explored. The development of an effective improved model for the implementation of TPM was investigated. Maintenance engineers and managers in any organisation can use this model to implement an effective TPM program. The seven-step TPM implementation model formed the basis for the compilation of a questionnaire. A survey was conducted to determine if an absence of TPM existed in a plastic painting plant. The results from the survey were drawn up and recommendations to further develop a model for the implementation of TPM was put forward.
- Full Text:
- Date Issued: 2007
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