Steps to be followed for world class manufacturing

1. World Class Manufacturing

2. A World-Class Manufacturer Means :…
It means being successful in your chosen market against any
competition—regardless of size, country of origin or resources.

3. It Means :
It means matching or
exceeding any competitor
from anywhere on
• Quality
• Innovation
• Innovation
• Lead-time
• Flexibility
• Cost
• Customer service

4. It means you are in control and your competitors struggle
to emulate your success.

5. Are you a world class manufacturing company?
Take a test to know if you are a world class manufacturing company by clicking
on the globe given on the right.

6. 7 steps to world class Manufacturing
1. Focus on ‘Competitive Quality’
2. Implement Lean manufacturing
3. Achieve cost efficiency
4. Reduce Time-to-Market
4. Reduce Time-to-Market
5. Exceed Customer Expectations
6. Streamline Outsourcing Processes
7. Have a global perspective

7. 1. Focus on ‘Competitive Quality’
Six sigma
FMEA

8. 1. Focus on
‘Competitive Quality’
Today’s dynamic and turbulent
business environment has shifted the
focus of the organizations from
“Quality” to “Competitive quality”.
With ever changing customer
requirements, quality is no more a
competitive weapon. Every
organization has quality today. What
separates a world class organization
For you its
internal
bleeding!!
separates a world class organization
from others is - how better you are
from the rest of your competitors.
Everybody in the organization must
think and demonstrate that they can
do better. The need of the hour is to
constantly challenge the status-quo
and develop a constructive level of
dissatisfaction with the present
performance.
Six sigma
FMEA

9. 2. Implement Lean Manufacturing
systems
Lean manufacturing is an overall methodology
that seeks to minimize the resources required
for production by eliminating waste (non-
value added activities) that inflate costs, lead
times and inventory requirements, and
emphasizing the use of preventive
maintenance , quality improvement programs,
maintenance , quality improvement programs,
pull systems and flexible work forces and
production facilities.
Principles of lean include zero waiting time,
zero inventory, scheduling (internal customer
pull instead of push system), batch to flow
(cut batch sizes), line balancing and cutting
actual process times.

10. 3. Achieve cost efficiency
Costs are really just part of the
scoreboard. When a company
implements world-class
operational processes, it improves
multiple measurements
Cost of Quality
Quality,Cost & Profit
multiple measurements
simultaneously,including cost,
lead times, inventory and
customer service.
Cost of Quality
Non-Value Adding Activities
Mistake Proofing
Pokayoke
Reducing Defectives through FMEA
Waste Reduction
Waste Assessment
Gemba Kaizen - A low cost approach
Design of experiments
Controlling variation
Analysis of variance

11. Time based competition
Risk Analysis
Risk Management
Creativity & innovation
Time based competition
New product development
SCAMPER
Ten commandments of time
Niche Marketing
4. Reduce Time-to-Market

12. 4. Reduce Time-to-Market
Customers now penalize suppliers that
infringe on their time, whether
through delays, mistakes or
inconveniences. Today’s customers
demand operations that are airborne,
on-line and real- time. Soon is not the
answer the customers want to hear.
They count the speed of response
Time based competition
answer the customers want to hear.
They count the speed of response
time as a Key Value Dimension.
Good ideas are not enough; well-
managed processes for bringing new
products to market faster than the
competitors can lead to significant
competitive advantages. Bringing
products faster into the market does
represent some element of risk,
which can be properly evaluated.
Risk Analysis
Risk Management
Time based competition
New product development
Ten commandments of time
Niche Marketing

13. 5. Exceed Customer Expectations
Are you a customer driven org.
Customer expectations
Customer expectations
Customer satisfaction measurement
Customer loyalty
Customer practices of global leaders
Internal health
Customer supplier model
Quality
Quality management principles
Exceeding expectations
Customer survey forms
Quality Function Deployment
Competitive Edge
Quality MIS

14. 5. Exceed Customer Expectations
The ultimate key to success
in any business enterprise is
to please your customers.
The most successful
companies don’t just meet
Are you a customer driven org.
Customer expectations
companies don’t just meet
customer expectations,
they exceed them and beat
the competition by setting
the standards at a level that
makes it difficult, if not
impossible, for others to
surpass.
Customer expectations
Customer satisfaction measurement
Customer loyalty
Customer practices of global leaders
Internal health
Customer supplier model
Quality
Quality management principles
Exceeding expectations
Customer survey forms
Quality Function Deployment
Competitive Edge

15. Outsourcing of manufacturing operations is a common practice today
because it offers flexibility—the ability to change products or processes
rapidly—and can often save money by exploiting economies of scale or
other favorable cost factors the contractor has to offer.
6. Streamline Outsourcing Processes
Process classification framework
other favorable cost factors the contractor has to offer.
For manufacturers, the fastest and easiest way to achieve this goal is
through partnerships with companies that have attained superior
capabilities in particular phases of the process-like production.
By partnering with world-class contract manufacturers you can reap the
benefits almost immediately—well-managed processes, high quality, on
time deliveries—and increase your performance and deliver to meet your
customer’s expectations. At the same time you can focus your own
resources on things that you do best-product innovation, design, marketing,
distribution sales or manufacturing.
Principles of outsourcing

16. 7. Have a Global perspective
International Marketing
Shingo prize for Mfg. Excellence

17. 7. Have a Global perspective
International Marketing
Shingo prize for Mfg. Excellence
7. Have a Global perspective
• There’s no question the world
is shrinking, and virtually every
business is now involved in
some form of international
trade—whether marketing
and selling to customers in
other countries or simply using
parts or materials that are
produced elsewhere.
Customers today are looking
for world class products.