Professional Documents
Culture Documents
used to be ....
Plug & PRAY
Now it is ...
Plug & Play
Used to be
Long waiting lines ...
Now it is ..
Faster Delivery . . . . .
Used to be
Traditional Products ..
Now it is ..
Innovative Products
Virtual
Keyboards
Used to be Mass
Production ..
Companys specification
This is it.
Lena hai to Lo ,,,,
Now it is ..
Mass customisati
Dells confugure your
Own PC
It used to be error
prone products ..
Now it is ..
Mistake Proof Products ..
Used to be manually
crafted ..
Now it is ..
Automation ..
That is it ..
Felt the difference
That is WORLD CLASS
MANUFACTURING
World Class
Manufacturing
A position of international
Dimensions of
competitiveness
Cost or price
Quality
Product or service differentiation
Dependability as a supplier
Reliability
Flexibility
Speedy delivery
Customer service
Employee productivity and managerial
expertise
R&D
Failure to take advantages of strengths &
opportunities and / or failure to recognize
own weakness and competitive threats
Neglecting production strategy
Too much emphasis on product and service
design at the expense of process design
Neglecting investments in capital and human
resources
Lack of good internal communication and
cooperation among different functional areas
Failure to consider customer need and want
Manufacturing management
contribution to strategy
Operations
Decisions
Quality
Product
Process
Location
Layout
Human resource
Supply chain
Inventory
Scheduling
Maintenance
Low Price
Delivery
Speed
Dependability
Quality
Conformance
Performance
Manufacturing Excellence
Manufacturing excellence can be
obtained by
Value Added Engineering
Do nothing that does not add value to the
product or to the customer
Continuous Improvement
Management
20 characteristics to
become world class
1. Lead Time Reduction
There is a plant-wide initiative to
measure and continually reduce lead
times. Non-value-adding steps in the
mfg. process are gradually
eliminated and dock-to-dock velocity
is increasing.
20 characteristics to
become world class
2. Streamlined Flow
Where appropriate, a demand-based
flow or "pull" production strategy is
adopted, using kanbans and demand
flow techniques, to produce to order
rather than to stock.
20 characteristics to
become world class
3. Quick Changeover
Quick changeover methods are
employed to increase equipment
availability and respond quickly and
economically to changing schedules
and customer needs.
20 characteristics to
become world class
4. Cellular Mfg. (Focused
Factories)
The facility is structured into
product- or customer-focused work
groups housing all operations to
manufacture a family of products.
Office operations are similarly
structured to increase accountability,
response time and quality while
reducing inventories and backlogs.
20 characteristics to
become world class
5. Empowered Teams
Employees are multi-skilled
members of motivated, capable work
groups with clear roles,
responsibilities and performance
standards.
20 characteristics to
become world class
6. Cross-Functional Teamwork
There is a high level of teamwork
and coordination between
organizational units and strong
internal customer-supplier
relationships.
20 characteristics to
become world class
7. Associate Involvement
&Commitment
Shop floor employees routinely solve
problems, suggest and implement
improvements and are committed to
world-class performance.
20 characteristics to
become world class
8. Process Reliability
A formalized system is in place to
maximize equipment uptime and
reduce variation in product quality.
Overall Equipment Effectiveness
(OEE) measures are at world-class
levels.
20 characteristics to
become world class
9. Continuous Improvement
Employees are engaged in CI
and/orKaizen Events on a regular
basis. All teams meet to set goals,
solve operating problems and
implement corrective action.
20 characteristics to
become world class
10. In-Process Quality
Product quality is built-in at the
operating level. Employees have the
ability and the authority to make
product quality decisions in process
and quality management tools (SPC,
error-proofing, etc.) are in place.
20 characteristics to
become world class
11. Seamless Shift Operations
Continuity, consistency and
communication are maintained
across shifts. An effective 24-hour
management system provides the
necessary support for all shifts. Shift
schedules satisfy both operational
and employee needs.
20 characteristics to
become world class
12. Standard Operating
Procedures
The plant is ISO (or QS) certified.
Operating procedures and quality
standards are consistent and a
formalized process is used to ensure
sustainability.
20 characteristics to
become world class
13. Goal Deployment
Key performance indicators and shop
floor goals are in place for each area,
developed at the operating level and
tied directly to plant goals
20 characteristics to
become world class
14. Visual Management Systems
Plant and team scoreboards and
other visual means of controlling and
improving operations are used
throughout the plant. Operational
status information is available
quickly and accurately to anyone
who needs it.
20 characteristics to
become world class
15. Incentives, Rewards &
Recognition
There is an effective incentive and
recognition system that promotes
continuous improvement and
rewards outstanding individual, team
and plant performance.
20 characteristics to
become world class
16. Plant Safety, Loss Prevention
&Housekeeping
Effective training & awareness,
thorough incident investigations and
a 5S organization program ensure an
orderly, efficient and safe workplace.
20 characteristics to
become world class
17. High-Performance Leadership
All levels of plant leadership provide
coaching, training & mentoring to
subordinates, encouraging peak
performance and employee
involvement.
20 characteristics to
become world class
18. Supplier Partnerships
The organization collaborates with a
few key certified suppliers to
continuously improve material cost,
quality &delivery, benefitting all
involved.
20 characteristics to
become world class
19. Cross-training &Multi-skilling
Multi-skilling in each area provides
the needed flexibility. Training of all
personnel, including the plant
leadership team, is a key priority.
20 characteristics to
become world class
20. World-Class Performance
Measures
Performance metrics measure
performance against world-class
standards, are generated and
controlled by shop floor personnel
and are successful in rallying the
entire organization toward higher
performace levels.
Tools of WCM
POKA YOKE
This is known as MISTAKEPROOFING
From Japanese:
Yokeru (avoid)
Poka (inadvertent errors)
Everyday
Examples
Stove A
Stove B
Pull
Push
Tools of WCM
Seiri : Sort
Seiton : Set in Order
Seiso : Shine, Clean
Seiketsu : Standardize
Shitsuke : Sustain
5 S
Tools of WCM
Six Sigma
What is good enough?
every hour
Six Sigma
Six Sigma Quality Standard Means
3.4 defects per million
0.00034 % defectives
99.99966 % good products
Tools of WCM
Kaizen
Meaning
Small Improvements
At all levels of
organisation
Kaizen
Tools of WCM
Total Quality
Management
Continuous improving
Involvement of everyone
Customer satisfaction
Tools of WCM
Standardization
Standardization
ISO 9000 standard
Quality Management System Standard
ISO 27000
System Security standard
ISO 22000
Food & Hygiene Standard
OHSAS
Occupational Hazard & Safety Standard
Deming Award
JIPM Award
European Award
Balwich Award
Yitzhak Rabin Israeli National Quality Award
Deal of Distinction Award
National Medal of Technology: Highest honor for
technological innovation, Presented by President of
USA
MDA Green Award
Platinum Health Award,
Health Promotion Board,
International Design Excellence Awards,
The Most Influential Advertising Award
Deming award
Instituted in 1951 by the Union of Japanese
World Class
Companies