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Definition:
World class manufacturing is a collection of concepts, which set standard for production and manufacturing for another organization to follow.
Japanese
manufacturing is credited with pioneer in concept of world-class manufacturing. World class manufacturing was introduced in the automobile, electronic and steel industry.
World class manufacturing is a process driven approach where various techniques and philosophy are used in one combination or other. Some of the techniques are as follows:
Make to order Streamlined Flow Smaller lot sizes Collection of parts Doing it right first time Cellular or group manufacturing Total preventive maintenance Quick replacement Zero Defects Just in Time Increase
Flexibility & control to satisfy customer on time, every time Managing through people, teams and aligning all to goals Reduction of waste in the manufacturing system
Focus Areas:
World class manufacturing is a process driven approach where various techniques and philosophy are used in one combination or other. Some of the techniques are as follows: Make to order Streamlined Flow Smaller lot sizes Collection of parts Doing it right first time
Cellular or group manufacturing Total preventive maintenance Quick replacement Zero Defects Just in Time Increase consistency Higher employee involvement Cross Functional Teams Multi-Skilled employees Visual Signaling Statistical process control
Implementation
Implementation with Discipline
There are three main principles, which drive world-class manufacturing. Implementation of just in time and lean management leads to reduction in wastage thereby reduction in cost. Implementation of total quality management leads to reduction of defects and encourages zero tolerance towards defects. Implementation of total preventive maintenance leads to any stoppage of production through mechanical failure.
Quality
Cost
Workplace Organizatio n
Maintenanc e
Logistic
Focus
Productivite
Service Level
Target
0 Defect
0 Waste
0 Breakdown
0 Stock
0 Accident
The main aspects of the world-class manufacturing are as follows: Industrial culture area Market/client area Product development area Operations area E-Performance area
Fiat Group Chrysler Royal Mail Volvo Ariston Thermo Group Mahindra & Mahindra Bombay Dyeing Reynolds India Hindustan Paper Corporation Ltd Haldia Petrochemicals Emani Group Mittal Dhatu RashayanUdo
EXAMPLE OF WCM
The WCM studies are carried out in about 150 factories of Fiat and Chrysler Group.
Factory
TOFA, which has been selected as the the first Silver Factory of FIAT Group in 2009 with a 62-point WCM audit score, is trying to be the first Golden Factory surpassing the 70-point in this year.
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