World Class Manufacturing - Analysis on Hayes and Wheelwright foundation

1. WORLD CLASS MANUFACTURING
An Investigation of Hayes and Wheelwright`s Foundation
BARBARA B.FLYNN, ROGER G. SCHROEDER, E.JAMES FLYNN

2. ABSTRACT OF THE JOURNAL
World Class Manufacturing Definition.
Practices of WCM termed by Hayes and Wheelwright Vs.
Recent Perspectives.
Tradeoffs Vs. Synergies of Competitive Performance of
WCM with current Descriptions of WCM.

3. WORLD CLASS MANUFACTURING
Defined based on
 Set of Stages of Manufacturing strategic role in Organization.
 Framework
for
Manufacturing
Infrastructure.
 Product – Process Matrix.
Strategy
Structure
and

4. HAYES & WHEELWRIGHT SIX PRACTICES
OF WCM
WORKFORCE SKILLS & CAPABILITIES
MANAGEMENT TECHNICAL EXPERTISE
COMPETING THROUGH QUALITY
WORKFORCE PARTICIPATION
REBUILDING MANUFACTURING ENGINEERING
INCREMENTAL IMPROVEMENT APPROACHES

5. RECENT PERSPECTIVES
• WCM based on Quality Management and JIT
• First developed by SCHONBERGER – 16 Principles of WCM.
• And Second by GIFFI, ROTH & SEAL – Attributes for WCM.

6. HAYES & WHEELWRIGHT PERSPECTIVE
VS RECENT PERSPECTIVE
HAYES &
WHEELWRIGHT
SCHONBERGER
GIFFI, ROTH & SEAL
Workforce Skills &
Capabilities
Employee Development by
Cross Training & Job
Rotation, Rewards &
Recognition
Technology Development
(Knowledge and Skill
Development)
Management Technical
Competence
Ignored
Advance Technology
Knowledge
Competing through
Quality ( Design)
Customer Needs and Rate
of use
Customer Closeness
Workforce Participation
Continuous Improvement
Cross Functional Teams,
Worker –Manager
Relationship
Rebuilding
Manufacturing
Engineering
Simple Equipment
Infrastructure Support

7. NEW MANUFACTURING PRACTICES
• TOTAL QUALITY MANAGEMENT(TQM)
• JUST IN TIME (JIT)
• CONTINUOUS IMPROVEMENT ( KAIZEN)

8. COMPETITIVE PERSPECTIVE
(TRADEOFFS VS SYNERGIES)
• DEPENDENT VARIABLES
COST
QUALITY - PERFORMANCE
QUALITY – FEATURES
DEPENDABILITY – SPECIFICATIONS
DEPENDABILITY – ON TIME DELIVERY
DEPENDABILITY – SERVICE
PRODUCT FLEXIBILITY
VOLUME FLEXIBILITY

9. COMPETITIVE PERSPECTIVE
(TRADEOFFS VS SYNERGIES)
• INDEPENDENT VARIABLES
 EMPLOYEE DEVELOPMENT
MANAGEMENT TECHNICAL COMPETENCEM
DESIGN FOR CUSTOMER NEEDS
WORKER PARTICIPATION
PROPRIETARY EQUIPMENT
CONTIONUOUS IMPROVEMENT
PROCESS CONTROL
FEEDBACK OF INFORMATION
JIT PRACTICES

10. RESEARCH
• Hypotheses
• Relationship between Hayes & Wheelwright`s WCM practices and
Competitive Performances.
H1
• H&W`S WCM RELATED TO COMPETITIVE
PERFORMANCE
H2
• QUALITY MANAGEMENT PROCESS
RELATED TO COMPETITIVE PERFORMANCE
H3
• CORE JIT RELATED TO COMPETITIVE
PERFORMANCE

11. METHODOLOGY
• SAMPLE
 Sample of three plants
 World Class Reputation ( Master list of WC Manufacturers )
 Traditional ( Metalworking Directory)
 Japanese Owned (Operating in US)
• DATA COLLECTION

Dependent variables & Independent Variables collected from Plant
Managers for Participation.
• ANALYSIS
 MULTIPLE REGRESSION ANALYSIS

12. CONCLUSIONS
• HAYES & WHEELWRIGHT WCM practices is strongly
related to Competitive performances.
• Significantly Related to Cost, Quality- Performance ,
Product Flexibility and Volume Flexibility.
• Synergies are found between different Perspectives of
Competitive Performances rather than Trade offs.
• Hayes & Wheelwright Practices lay down the way to
Modern WCM practices.

13. THANK YOU