pom world class manufacturing

8/8/2019 POM World Class Manufacturing

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WORLD CLASS MANUFACTURING

Presented by:

B. Pavana Harish

Soumya Ranjan Panda

Sadhana Mishra

Anish Rizwan

Viplav Vijay Choubey


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WORLD CLASS MANUFACTURING

It refers to the practice followed in a manufacturing

organizations, in order to consistently deliver

exceptional performance, frequently in excess of

expectations.

World Class Manufacturers are those that

demonstrate industry best practice

IBA, Academic purposeonly

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Leaders in world class manufacturing

leader in manufacturingpractices

Toyota Motors

General Electric Boeing Corporation

Honeywell, Rockwell

NCR

ITT industries

Motorola

These companies haveset the trend s formanufacturing quality.

Other companies areadopting quality andimprovement toolsbeing used by theseorganizations

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Principles behind world class

manufacturing

Just in Time or Lean Manufacturing, the step by step

elimination of waste

total quality, Total quality is often these days called

Six Sigma

total preventative maintenance -unplanned

stoppages due to equipment failure are minimized.


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How to achieve world class

manufacturing

Develop the awareness of the need to make the

transition to World Class Manufacturing

Develop the ability to search for relevant tools and to

apply them effectively

Monitor progress so that an improvement program

can be systematically utilized


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Tools to measure and record process (1/2)

Critical SuccessFactor World

ClassManufacturing tool Measurement Indicators

Cost control Just-in-time logistics,

quality at source and SCM tools

Inventory holdings

Absence of defects and

rework

Cost of incoming

materialsQuality Statistical Process Control,

fool-proofing to prevent

errors, Pareto analysis of

types and causes of

production defects

Customer return rates

Internal reject, rework

and scrap rates

Supplier quality

performance

External flexibility Just-in-time logistics,

quality at source and supply

chain management tools

Time from customer

order to delivery

Delivery frequency and

reliability to customers

Delivery frequency and

reliability of suppliersIBA, Academic purposeonly

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Tools to measure and record process (2/2)Critical Success Factor World Class

Manufacturing tool

Measurement Indicators

Internal flexibility Cellular layouts, single unit

flow, production pulling,

kanban signaling system,

single-minute exchange of

dies for rapid machine

Machine changeover

times

Batch and lot sizes

Inventory levels

Throughput timeCapacity to change

(Human resource

development)

Multi-tasking, multi skilling,

quality circles,

kaizen groups, training,

incentive schemes.

Numeracy and literacy

levels

Labor/management

turnover levels

Absenteeism rates

Training expenditureand types of training

Employee development

Innovation capacity Concurrent engineering,

new product development

techniques

R&D expenditure

Proportion of sales from

new products


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Factors which can make a WCM

Organization(Team Work)

Flexibility

Discipline

Equality

TeamAutonomy

De-layeringManagement

CellOrganization

Leads toOwnership

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International benchmarking Benchmarking is the process of comparing organization's

practices with the best in class organization.

The purpose of this tool is to enhance productivity, Quality,

Customer satisfaction and reduction in cycle time or lead time

by comparing practices of that best class organization.

Recognized Standards:

ISO 9001:2008 (QMS) (Quality Management System)

ISO 14001:2004 (EMS) (Environmental Management System)

ISO 27001:2005 (ISMS) (Information Security Management System)


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Awards

Malcolm Baldrige National Quality Award this award is given

to those organizations, which perform best in the following

seven categories:

1. Leadership

2. Process Management

3. Customer & Market Focus

4. Strategic Planning

5. Workforce Focus6. Measurement, Analysis and Knowledge Management

7. Results


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Some models

Lean Manufacturing developed by Japanese is focusing onproviding best quality product to the customer, within theminimum possible time, on the targeted place with minimumwaste of material, labor, space and time

Total Productive Maintenance developed by Japanese is notmerely a maintenance tool, but it has unified operator andmaintenance person. They both are responsible for safe, cost

effective operation of machine or equipment


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THANK YOU

pom world class manufacturing

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