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UNIVERSITY OF THE WESTERN CAPE
FACULTY OF ECONOMIC MANAGEMENT SCIENCES
SCHOOL OF BUSINESS AND FINANCE
OPERATIONS MANAGEMENT
MAN 233
TUTORIAL SUBMISSION:
4
DUE DATE:
25 October 2021
TUTORIAL GROUP:
6
PAIR GROUP:
PARTNER STUDENT DETAILS
NAME & SURNAME
STUDENT NUMBER
CONTRIBUTION %
Anele Zuma
3956833
100%
Kamogelo Gosego Gigi
Merafe
3952831
100%
1. The common wastes that are presented within the methodology of Lean Production are: Waiting time waste,
Transportation waste, Inventory waste, Unnecessary Motion waste, Product defect waste, and over
production waste.
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Product Defect Waste : Ford addressed the Product defect waste which may influence customer satisfaction
which could in the end result in customers serving their relationship with the organization. Product defects
can lead to costs in repairing the product and wasting raw materials , and labour , processing time and
capacity . In the case study , it is mentioned that the cost in energy and labour to recover all vehicle material
often exceeds the value of the materials and offers insignificant value to the environment . Therefore making
it a waste . Product waste is seen through the company increasing the renewable and recycled materials
with the tangible as soy and bio-based seat cushions and seatbacks on the 2010 Ford Taurus, and just the
fact that Ford is advancing the use of eco-friendly materials in the industry.
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Overproduction waste : Overproduction waste occurs when a product or products are produced before
required or produced in excess of the predicted demand . With regards to the above case study . Ford had
already bio-based foam on more than 2 million vehicles yet they do not know what the demand will be like .
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Unnecessary motion waste is another lean production discussed. Unnecessary motion waste is induced by
humans and is a direct consequence of the manner in which employees perform their tasks. Unnecessary
motion waste is seen through the fact that more than 2 million vehicles are wanted to be converted
according to them 100 percent of their fleet into it in the future. This doing is them wanting to advance the
use of eco-friendly materials in the industry. 100 percent usage of recycled yarns can mean a 64 percent
reduction in energy consumption and 60 percent reduction in CO2 emissions compared to the use of ne
yarns which implies to unnecessary motion waste.
2. The Kaizen technique is one of the lean manufacturing techniques applied in the case study as it is a
systematic approach that includes all operations within the organization and aims to improve the quality of
products and components that are delivered to customers . The improved quality is achieved through the
elimination of errors or waste . The kaizen technique was seen in 2007, when Ford became one of the first
automakers in Europe, requirements including: Design and produce vehicles that facilitate the dismantling,
reuse, recovery and recycling of them at end of life, reducing the hazardous substances when designing
vehicles, increasing of the use of recycled materials in vehicle manufacture, and ensuring that parts do not
contain mercury, hexavalent chromium, cadmium or lead.
In the case study , the company increased its use of renewable and recyclable materials with examples as
tangible as the soy and bio-based seat cushions and seatbacks on the 2010 Ford Taurus and that is just one
way that Ford is advancing the use of eco-friendly materials in the industry. Therefore in this sense , the
company aims to achieve improved quality through elimination of errors and waste .
Standardization is one that is used as well as its most optimal use is to manufacture a wide range of variety
items from a small number of standard components and materials . A typical example of a high-volume ,
mass production organization is the motor industry , where customers are offered a variety of models to
choose from. The costs are kept low by designing the vehicles to use standardized components as seen in the
case study .
Matching demand and production can be seen when material engineers are seen in the process of
determining if recycled polymer can be used for similar components in the global Focus coming the North
America and Europe in 2011. The 5S which is to sort, straighten, shine, standardize and sustain which is seen
through Ford wanting to concentrate on increasing the use of non-metal recycled and bio-based materials.
The bio based usage which results in reduction in petroleum oil usage, post consumers, used to make under
body systems and radiator air defector , post industrial recycled yarns and repurposed nylon carpeting , and
lastly the automotive industry .
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