| dc.description.abstract | This study focuses on optimising operations effectiveness and capacity at a heavy
engineering plant, namely Heavy Engineering Vereeniging, a division of DCD–DORBYL (Pty)
Ltd. The implementation and adoption of technology was included in the investigation. The
company operates from 2 premises in Vereeniging and Vanderbijlpark (Gauteng), and
consists of 5 factory buildings.
A literature review was conducted to ascertain current industry best practises and
technology implementation initiatives. This review included a discussion on the following
aspects: Capacity and its utilisation, flexible technology and advanced manufacturing
systems, technology in manufacturing, capacity expansion and scheduling, factory layouts,
technology and capacity utilisation in a South African context, and finally future trends in
capacity and technology at Heavy Engineering Vereeniging.
Data collection from within the organisation was done via the issuing of a questionnaire and
conducting interviews with various management and supervision employees. The gathered
data was analysed for employees’ opinions on current utilisation of capacity and use of
technology, as well as suggestions regarding improved working methods, factory layout and
the implementation of new technology. The quantitative data was analysed using the
Statistical Package for the Social Sciences software, with the provided descriptive statistical
test results used for the identification of possible trends and further interpretation.
It was found that current capacities and equipment are being well utilised, but not to their
optimal level. The well entrenched management information systems, measurement systems
and operating procedures currently in use will aid to increase the level of utilisation of the
available capacity and equipment. The implementation of technology and latest best
practises within the operation will gain HEV a competitive edge, ensuring their future
sustainability and market leadership. However, this implementation must be done with the
input and buy in of the work force. The variances in perceptions and attitudes between the
various job functions, discovered during the statistical analysis, must be taken into
cognisance during any capacity optimisation or technology implementation initiative.
Continued capital expenditure and the current drives in research and development need to
be maintained to further ensure sustainability.
Various inefficiencies were identified and recommendations were made to improve the
current operation’s effectiveness and factory layout, primarily by decreasing operating
inefficiencies.
The recommendations were made based on the results of the study and included the
expenditure involved in their execution. Financially viable options, calculated using payback
periods and net present values (NPV), included the purchase of phased array ultrasonic
testing equipment, horizontal SAW for longitudinal flanges and a modular type furnace.
Other options, which could improve operations effectiveness, but not returning financially
positive results, included the moving of the Hausler roll into the main fabrication workshop
and the moving of the Sachems drills to alongside the lathes.
A number of new processes and initiatives were recommended, for which cost comparisons
to current similar practices could not be performed. These included the full production
implementation of the punch through tandem arc submerged arc welding for wind turbine
tower manufacture, implementation of a customer interfacing and communication platform
and internal communication display boards. Current practises regarding touch time
measurements for welding and drilling were validated.
By undertaking these recommendations, it was felt that HEV would continue to be wepositioned to capture the predicted ongoing growth in the mining market in which they
currently operate, and to fully benefit from the future upturn in the energy market. | en_US |
