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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