Improving the Waste Supply Chain at the Ford Automotive Company South Africa

Abstract

DHL Supply Chain is a logistics company with various specialities. One of these specialities is in the manufacturing automotive sector. Ford Motor Company South Africa is one of the manufacturing companies making use of the DHL Supply Chain logistical expertise. DHL Supply Chain managers have identi ed areas needing improvement within the Ford Motor Company South Africa waste supply chain. This supply chain is divided into two processes in this report - the rst process being the recyclable waste supply chain process and the second the returnable TrenStar bin waste supply chain process. The packaging waste restricts the ow of the assembly process and any other movement in the facility. There is a need to improve the ow of the waste materials through the facility as well as to ensure that the waste is not on the oor for extended periods of time. Managing the waste currently requires more resources than necessary. The aim of this project is therefore to optimize the ow of the packaging waste materials through the facility to save resources and increase space. Each process was individually analysed using process ow mapping, and the prob- lematic process steps identi ed. Using the 5W1H method, the root causes of the problem areas were pinpointed. The problem areas as well as the root causes were used to establish possible solutions. In the literature review, industrial engineering areas such as quantifying measure- ments, material handling, supplier relationships and 5s were researched. Each engineering area has relevant techniques and tools to establish solutions for the identi ed problems. These techniques and tools were used to develop a research approach which was followed throughout the solution determination process. A quanti cation model was developed to quantify the waste generation amount. From there the material ow solutions with regards to the facility layout and material handling equipment were narrowed down. Possible solutions for each problematic process step were constructed within the chosen sections. The solutions were categorized according to the industrial engineering areas and the techniques used to establish the solution. The solutions were then compared to determine the optimal interim corrective actions as well as the permanent corrective actions. Ten corrective actions have been recommended in the conclusion to expedite the ow of the waste materials through the facility as well as to decrease the resources required to handle the waste materials. The recommendations would also decrease the time waste packaging materials would spend obstructing horizontal space.