| Summary: | This thesis examines and develops a proposed manufacturing system methodology
and quality control for the design, planning, scheduling and implementation of the
Thermiculite 866 high volume manufacturing line, through the use of Lean
Manufacturing, Total Quality Management and Change Management principles. The
concept under investigation extends to the analysis of flow production benefits and
restrictions considering specific characteristics of the product. A novel factory design
methodology is proposed to achieve required production volumes and cost effective
implementation. Furthermore, high product quality levels are warranted by
developing a Strategic Alignment of Quality Function Deployment which brings
commercial awareness to the early stages in the product/process development, and
reduces the time to market it whilst promoting long-term solutions. The process and
the layout design are supported by a proposed Batch/Flow Comparative Matrix. As a
result, the proposed factory design methodologies and management of change
introduced in the organization led to a successful production system design as well as
controlled implementation according to stakeholders requirements. The design and
partial implementation of the Thermiculite 866 production line illustrates the
effectiveness of the methodology proposed in this thesis to manage and design the
equipment and quality for the future Thermiculite production line. === Technology Strategy Board for the Knowledge Transfer Partnership (KTP)
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