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World Class Manufacturing

• Aiming to compete for quality on a world wide market and becoming competitive in global market

• A position of international manufacturing excellence, achieved by developing a culture based on factors such as continuous improvement, problem prevention, zero defect tolerance, customer-driven just-in-time production, and total quality management

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Introduction

• Different set of concepts, principles, policies and techniques

• Driven by results• Primarily focuses on continuous improvement in quality,

cost, lead time, flexibility, reliability, innovation and customer service

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Factors of WCM

Organization (Team Work)

Flexibility

Discipline

Equality

Team Autonomy

De-layering

Management

Cell Organizatio

n

Leads to Ownership

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Check Points for WCM (Contd…)

• Timely delivery• Knowledge of key customers and competitors• Authority and empowerment to staff • Elimination of central storage of direct materials and supply

of purchased material to the point of use without routine inspection

• Training and development of existing employees

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Check Points for WCM (Contd…)

• Reduction of set - up time and economical batch sizes• Active policy to help keep work areas clean, tidy and

uncluttered• Culture of continuous improvement in customer service• Mechanism to quickly and effectively receive and evaluate

suggestions from all employees

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Objectives of Global Production

• Reduce costs ( labor, taxes, tariffs etc.)• Reduce risks ( foreign exchange)• Improve supply chain• Provide better goods and services• Attract new markets• Learn to improve operations• Attract and retain global talent

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When in doubt

move it out Red

Tag Technique

A place for everything

and everything in its place

Clean and inspect or

inspect through cleaning

Make up the rules

follow and enforce

them

Part of daily work

and it becomes a

habit

5S Explanation

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Kaizen

• Continuous improvement involving everyone• Business strategy involves working together to make

improvements without large capital investments• Setting doable, replicable standards and then continually

improving those standards• It is not all about incentives and rewards—it is about the

support given to front-liners to help them improve the way work is done

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Lean Manufacturing (Contd...)

• Lean Manufacturing is a Team Based continuous improvement process designed for long term maximization of company resources

• Lean Manufacturing is an approach to achieve manufacturing excellence based upon the continuous elimination of waste

• Waste is defined as activities that do not add value to the product

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Lean Manufacturing (Contd...)

• Lean Manufacturing utilizes techniques and principles that improve efficiencies of value added activities

• Value Added Activities : Transform raw materials and information into parts or products

• Non - Value Added Activities : Consume resources that do not contribute to the physical changes of the product

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7 Wastes

• Over production• Waiting• Transportation• Unnecessary inventory• Inappropriate processing• Excess motion• Defects

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Pressures Requiring Companies To Become Lean

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Traditional Vs. Lean Manufacturing in Time Scale

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Characteristics of Lean Manufacturing

• Waste Elimination• TAKT Time / Line Balancing• Point of Use / Kanban• Error Proofing • Inspection• Visual Factory • Flexible Low Cost Automation

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Results of Lean Manufacturing

• Reduced Costs• Reduced inventory• Reduced WIP• Reduced Cycle Times• Reduced Scrap• Improved Quality• Increased Productivity• Improved Utilization of Space

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Flexible Manufacturing

• Manufacturing system which allows flexibility into the system to respond to changes.

• Two types - Machine Flexibility - Routing Flexibility

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Advantages and Disadvantages of FM

Advantages• Reduced manufacturing time• Lower cost per unit produced• Greater labor productivity• Greater machine efficiency• Improved quality• Increased system reliabilityDisadvantages• Cost to implement• Substantial pre-planning required

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Just In Time Manufacturing

• Just in Time manufacturing is a systems approach to developing and operating a manufacturing system

• JIT means making what the market wants, when it wants it.• JIT has been found to be so effective that it increases

productivity, work performance and product quality, while saving costs         

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Just In Time Characteristics

• Accurate demand forecast• Low inventories• Small lot sizes• Quick / low cost setups• Multifunctional workers• Reliable vendors• Problem Solving• Continuous improvement

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Method & std.

Cost deployment

Workplaceorganization

Quality Maintenance Logistic

Safety

Method & std.

Focus

Target

Values People involvement, value creation, customer satisfaction

Total industrial engineering

Total quality control

Total productive maintenance Just in time‐ ‐

Productivity Qualityimprovement

Technicalefficiency

Service level

Zero inventoryZero defects Zero breakdownZero waste

WCM Objective

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WCM in action

Before After

52% elimination of ergonomic risks

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WCM in action

Before After

• Inventory reduced• Material delivered to point of use • 57% reduction in operator walk time

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• Improved work conditions

Before After

WCM in action

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Kanban

• Meaning – Signboard is a concept related to lean and just-in-time (JIT) production

• Kanban is one means through which JIT is achieved• Kanban cards are a key component of Kanban that uses

cards to signal the need to move materials within a manufacturing or production facility or move materials from an outside supplier to the production facility