Question 1 (20 Marks)

Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity. Waste is seen as anything that customers do not believe adds value and are not willing to pay for. Provide an overview on the principles of lean and then evaluate how it could improve efficiency in your organisation.

Question 2 (20 Marks)

5S is a systematic way of organizing workplaces by eliminating waste, improving flow, and reducing the number of processes where possible. It is pioneered by Toyota Motor Company that applies the standard housekeeping practices in the workplace through the five principles. Demonstrate using appropriate examples how you would apply the 5S principles.

Question 3 (20 Marks)

Cost of quality is a method for calculating the costs companies incur ensuring that products meet quality standards, as well as the costs of producing goods that fail to meet quality standards. Categorise the costs of quality for your organisation and then discuss how this could be eliminated, reduced or improved in your organisation.

Question 4 (20 Marks)

Total Quality Management (TQM) is a comprehensive system for achieving continuous improvement in customer satisfaction. It is a philosophy of total integration of the business to achieve the required result. Discuss one Total Quality Management (TQM) tool and critically assess how you could apply it to your organisation.

Question 5 (20 Marks)

Benchmarking is an approach that some companies use to compare their operations with those of other companies (preferably the best in the world). It is partly concerned with being able to judge how well an operation is doing. Benchmarking involves selecting a demonstrated standard of products, services, costs or practices that represent the very best performance for processes or activities very similar to your own. Conduct a benchmarking exercise for your organisation or department or unit.