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. - 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. - 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 . - 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 .
