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WorldClassManufacturingMeaninganditsPrinciples

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World Class Manufacturing

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Introduction

Manufacturing has evolved considerably since the advent of industrial revolution. In current global and
competitive age, it is very important for organization to have manufacturing practice which is lean, ecient,
cost-eective and exible.
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 rst time
Cellular or group manufacturing
Total preventive maintenance
Quick replacement
Zero Defects
Just in Time
Increased consistency
Higher employee involvement
Cross Functional Teams
Multi-Skilled employees
Visual Signaling
Statistical process control

Idea of using above techniques is to focus on operational eciency, reducing wastage and creating cost
ecient organization. This leads to creation of high-productivity organization, which used concurrent
production techniques rather than sequential production method.

World Class Manufacturers

World class manufacturers tend to implement best practices and also invent new practices as to stay
above the rest in the manufacturing sector. The main parameters which determine world-class
manufacturers are quality, cost eective, exibility and innovation.
World class manufacturers implement robust control
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techniques but there are ve steps, which will make the

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World class manufacturers implement robust control techniques but there are ve steps, which will make the
system ecient. These ve steps are as follows:
Reduction of set up time and in tuning of machinery: It is important that organizations are able to
cut back time in setting up machinery and also tune machinery before production.
Cellular Manufacturing: It is important that production processes are divided into according to its
nature, with similar nature combined together.
Reduce WIP material: It is normal tendency of manufacturing organization to maintain high levels of
WIP material. Increased WIP leads to more cost and decreased WIP induces more focus on production
and fast movement of goods.
Postpone product mutation: For to achieve a higher degree of customization many changes are
made to nal product. However, it is important that mutation conceived for the design stage
implement only after nal operation.
Removal the trivial many and focus on vital few: It is important for organization to focus on
production of products which are lined with forecast demand as to match customer expectation.

Principles of World Class Manufacturing

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 (total-quality-management.htm) 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.

Aspects of World Class Manufacturing

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

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Work Study and Industrial Engineering

Introduction
To survive in the current competitive and global environment, it is important for the organization to
continuously look at ways to improve eciency and productivity. It needs to discover a new, easy and costeective way of manufacturing or providing services.
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eective way of manufacturing or providing
services.

Work study and industrial engineering play important role in job simplication, job design, job enrichment,
value analysis/engineering, method analysis, operational analysis, etc. Work study has been utilized by
companies to job productivity. Industrial engineering is the latest method employed to improve productivity.
It deals with design, enhancement and setting up of engineering systems encompassing plants, machinery,
workers, etc.

Work Study
Work study uses techniques like method study and work measurement to understand human work
potential in terms of time spend on completing a task, looking at ways to make the task simpler and
easy, as to increase productivity and ewciency. Work study is eld used to nding ways of increasing on
job performance, optimum usage of plant and machinery, standardization of work methods, etc. Therefore,
objectives of work study are as follows:
Scientic and controlled analysis of existing available methods of executing a task.
Measuring performance of mentally and the physically qualied workers, establishing it as standard
for performance measurement.
Optimum utilization of workers, plant, machinery and other resources at minimum cost.
Improved productivity and enhance worker mood.
Increasing eciency of organization.
For an organization, productivity can be increased over a period of time, if workers are ecient and are
focused. Therefore, advantages of work study are as follows:
Increase in production eciency.
Higher levels of production and optimum utilization of resources.
Ecient ow of material and products.
Ecient handling of material and better layout.
Decreased cost of production as times spend on the job is decreased.
Increased morale of workers with an increase in safety and eciency.
Benchmark and standard performance level are established, thus providing targets for organization.
Better job satisfaction and incentive planning due to work study.

Method Study
It is a scientic process to better job design. It studies the existing job process and proposed job process as to
identify the appropriate job process which results in ecient and cost eective operations. Therefore,
objectives of method study are as follows:
To study existing work process and proposed work process.
To nd out new methods of increased production and reduction of cost.
To achieve optimum utilization of resources.
Method study ensures that there is an increase in overall productivity and protability of organization.
Method study involves following procedures:
Selection of work to be studied.
Recording the present method.
Critical examination of the facts.
Development of most practical, economic and eective method.
Installation of new method.
Maintenance of new method and practices checking

Industrial Engineering
Industrial engineering is concerned with developing the most eective and ecient way to use plant,
machinery, materials, etc. The main objectives of industrial engineering are as follows:
To increase productivity without incurring
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the incremental costs.

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To increase productivity without incurring the incremental costs.

To encourage automation as to decrease human intervention.
To develop ecient and eective operation work cycle.

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About the Author(s)

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