This document discusses concepts of world class manufacturing including definitions, factors, objectives, and examples. It defines world class manufacturing as aiming to compete on quality globally through continuous improvement, zero defects, and total quality management. The document outlines factors, check points, objectives, and examples of concepts like 5S, kaizen, lean manufacturing, and flexible manufacturing. It provides examples of how Indian companies have implemented these concepts.

1. World Class Manufacturing
By
Deepti Anand (066)
Rahul Hedau (073)
Amit Sharma (080)
Shilpa Sharma (087)
Komal Sachan (094)
Kanad Kale (101)
Manisha Mishra (108)
Ritika Mittal (115)
Tushar Mehta (122)

2. Definition
• 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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3. 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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4. Factors of WCM
Flexibility
Leads to
Ownership Discipline
Organization
(Team Work)
Cell
Organizatio Equality
n
De-
layering Team
Managem Autonomy
ent
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5. 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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6. 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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7. 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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8. 5S Explanation
When in
A place for Clean and Make up Part of
doubt
everything inspect or the rules daily work
move it
and inspect follow and and it
out Red
everything through enforce becomes a
Tag
in its place cleaning them habit
Technique
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9. 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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10. 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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11. 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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12. 7 Wastes
• Over production
• Waiting
• Transportation
• Unnecessary inventory
• Inappropriate processing
• Excess motion
• Defects
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13. Pressures Requiring Companies To Become
Lean
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14. Traditional Vs. Lean Manufacturing in Time
Scale
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15. 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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16. 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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17. Flexible Manufacturing
• Manufacturing system which allows flexibility into the
system to respond to changes.
• Two types
- Machine Flexibility
- Routing Flexibility
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18. Advantages and Disadvantages of FM
Advantages
• Reduced manufacturing time
• Lower cost per unit produced
• Greater labor productivity
• Greater machine efficiency
• Improved quality
• Increased system reliability
Disadvantages
• Cost to implement
• Substantial pre-planning required
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19. 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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20. 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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21. How does implementing WCM improve
productivity
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22. WCM Objective
Safety
Workplace
Cost
organizatio Quality Maintenance Logistic
deploy
n
ment
Method Total industrial Method
Total quality Total productive
Just‐in‐time
& std. engineering control & std. maintenance
Quality Technical Service
Focus Productivity efficiency level
improvement
Target Zero waste Zero defects Zero breakdown Zero inventory
Values People involvement, value creation, customer satisfaction
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23. WCM in action
52% elimination of ergonomic risks
Before After
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24. WCM in action
Before After
• Inventory reduced
• Material delivered to point of use
• 57% reduction in operator walk time
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25. WCM in action
Before After
• Improved work conditions
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26. 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
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27. Indian Scenario
• TVS Motors
– A leading two-wheeler manufacturer
– Winner of the top quality award -Deming award
• Tata Motors
– Acquiring Daewoo Motors-truck manufacturing in South Korea
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28. Indian Scenario
• Reliance Group
– Acquired Flag Telecom of USA
– One of the largest refining capacities in the world
– Second biggest producer of polyester fiber in the world-expecting
to buy out Australia’s largest polyethylene maker Quenos to
become the largest global player
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29. Indian Scenario
• Aditya Birla group
– Acquisition of copper mines in Australia
– Acquisition of Liaoning Black plant in China
– Acquisition of cement business from L&T makes them 8th
largest in the world
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30. Bibliography
• http://www.smthacker.co.uk/world_class_manufactu
ring.htm
• http://world-class-manufacturing.com
• http://www.leanrapid.com/manufacturing/world_cla
ss.asp
• http://en.wikipedia.org/wiki/Lean_manufacturing
• http://www.chrysler.com/en/
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31. Thank You
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