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7/31/2019 World Class Manufacturing ,16
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OPERATIONS MANAGEMENT
TOPIC:- world class manufacturing
Prepared & presented by
Santhilal s
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What is WCM
World Class Manufacturing, as one of the most known
production systems in the world, is a different set of
concepts, principles, policies and techniques for
managing and operating a manufacturing company. It is
driven by the results achieved by the Japanesemanufacturing resurgence following World War II, and
adapts many of the ideas used by the Japanese in
automotive, electronics and steel companies to gain a
competitive edge. It primarily focuses on continualimprovement in quality, cost, lead time, flexibility and
customer service
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World Class Manufacturing is a process-driven approach
where implementations usually involve the following
philosophies and techniques:
Make-to-order Streamlined flow
Small lot sizes
Families of parts
Doing it right the first time
Cellular manufacturing
Total preventive maintenance
Quick changeover Zero Defects Just-in-time Variability reduction High employee involvement Cross functional teams
Multi-skilled employees Visual signalling Statistical process control
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With WCM company will be highlycompetitive where:
the voice of customer is heard in
workshop
leaders have a passion for improvements
no types of wastes are accepted
methods for improvements are applied
strictly
all faults are visible People involvements are driving force of
change
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Four essential concepts of
WCM
Total quality control Total productivity maintenance
Total industrial management
Just in time
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Nature of WCM
Companies engaging in World Class Manufacturing strategies
focus on improving operations, strive to eliminate waste and
create lean organizations. This often results in higher
productivity. But these companies also focus on speed of total
throughput from order capture through delivery setting new
standards for delivery without the heavy dependence on
inventory. Instead of conventional reporting, WCM applies Cost
Deployment to the decision-making process. Cost Deploymentuses systematic analysis to identify the areas and types of
waste and losses, enabling the planning and prioritizing of
corrective actions and providing a method for evaluating results
achieved
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Ten pillars of WCM
1. Safety
2. Cost Deployment
3. Focused Improvement
4. Autonomous Maintenance / Workplace Organization
5. Professional Maintenance6. Quality
7. Logistics
8. Early Equipment Management
9. People Development10. Environment
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The most essentialpillars of
WCM
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The 5s of WCM
5S, abbreviated from the Japanese words Seiri, Seiton, Seison, Seiketsu,and Shitsuke, are simple but effective methods to organize the workplace.
The 5S, translated into English are: housekeeping, workplaceorganization, clean up, keep cleanliness, and discipline. They can bedefined as follows:
Housekeeping. Separate needed items from unneeded items. Keep onlywhat is immediately necessary item on the shop floor.
Workplace Organization. Organize the workplace so that needed items canbe easily and quickly accessed. A place for everything and everything in its
place. Cleanup. Sweeping, washing, and cleaning everything around working area
immediately.
Cleanliness. Keep everything clean for a constant state of readiness.
Discipline. Everyone understands, obeys, and practices the rules when in
the plant.
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7 tools of WCM
1. Prioritization (Find out important problems)
2. Systematic, logical and detailed deployment of objectives
into right means and right solutions, and measurement of the
results against the objectives and targets (to identify where
the problem is)
3. Problem description with sketches (Drawing sketches
requires better understanding of the problem in detail / to
understand the problem.)
4. 5s
5. Root-cause analysis (To identify true causes.
6. Phenomena description with sketches (Observe carefully
what are happening behind the problem.)
7. TWTTP Find hidden issues behind the problem
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7 Keys to World Class
Manufacturing"
Reduce lead times
Speed time-to-market
Cut operations costs Exceed customer expectations
Manage the global enterprise
Streamline outsourcing processes Improve business performance visibility
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THANKS
FORYOUR
T I M E