World Class Manufacturing

Purple HR Consulting Private Limited

104, Maple Wood
Opp. Aga Khan Palace
Yerawada, Pune: 411 006
www.purplehrconsulting.com
sudhirsohoni@purplehrconsulting.com +91 9823010099






World Class Manufacturing
What is World Class Manufacturing ?
World Class Manufacturing depends on martialing resources for continual rapid
improvement. This involves recasting relationship among Suppliers, Purchasers,
Producers and Customers.


- Prof. Richard Schonberger - 1986





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Copyright 2013.All Rights Reserved with Purple.
Industrial Growth
with
Mechanization,
Productivity
Increases
Substantially



1927






1922



Factories
Redesigned for
better use of
Electric Motors



1938



US Industrial
Production
Develops



1941



World War II



1947



Search for Low
Cost
Manufacturing
Areas



1949



R&D Departments
Widespread



1951


Exploiting
Wartime
Innovations



1954






1955



SQC for
Acceptable
Defect Level



1959



Project
Evaluation and
Review
Technique



1961 / 62



Critical Path
Method
(CPM)



1971 / 72



Focused Factory



1979



Robotics and
Numerical
Control



1981



Six Sigma Motorola



1982



Computer
Assisted Design



1983 / 84



Statistical
Process Control
for Quality



1986



Lean
Manufacturing



1989 / 90



Benchmarking
ISO Standard



1992



Process Re-
Engineering and
Outsourcing



1994



Supply Chain
Management



1995



Six Sigma Central
in Strategy



1996



World Class
Manufacturing
World Class Manufacturing
Manufacturing Excellence Initiatives Over Last 90 years


World Class Manufacturing
How each of these initiatives deferred?
IE : Zero Waste
TQM : Zero Defect
TPM : Zero Default
JIT : Zero Stock
TEI : Zero Injury





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WCM : Integrates IE,TQM, TPM, JIT, TEI, Six Sigma, Lean & Kaizen


World Class Manufacturing
What is Unique?
Flexible Logistics
Rapid Changeover and Machine Flexibility
Focus on quick New Product Development
Inspection Eliminated
Empowered Workers Problem Solving, Widespread Idea Contribution



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World Class Manufacturing
What will your company achieve by adopting WCM?
Customer Satisfaction
Assured Quality
Quick and On Time Deliveries
Maximize Inventory Turns
Highly Engaged Workforce
Least Cost Manufacturing




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World Class Manufacturing
How will we make it happen?
Step 1 : Through Diagnostic
Step 2 : Identification of Priorities Creating a Work Plan
Step 3 : Widespread Workforce Involvement
Step 4 : Structured Problem Solving
Step 5 : Weekly, Monthly, Quarterly Reviews segmented on Lead Time Articulation




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People in Purple
Copyright 2013.All Rights Reserved with Purple.

Sudhir Sohoni
Sudhir is an alumnus of TISS 1980 Batch and in his 30 years worked with WIMCO,
Metal Box India, Hindustan Unilever, RPG Group and Thermax. For the past 15
years has been working at the strategic level and holds expertise in designing
organizations for growth and profitability. He is the Founder of Purple HR
Consulting.


Anup Gandhi
Anup is a seasoned, 30+ years experienced hard core manufacturing person,
managed heavy engineering factory set up with 1200+ workforce, as a factory
manager. Anup is a Mechanical Engineer graduated from Govt. College Of
Engineering, Amravati, Nagpur University ( 1979) & done Master in Management
Science ( MMS) from Symbiosis Institute; Pune University (1984).
Anup has undergone intensive coaching from Japanese Sensai Mr. Takao
Kasahara San, Mr. Masaki Imai San & Indian Sensai Mr C Narsimhan on the
Manufacturing Excellence Programs. He has implemented TQM, TPM, Lean and
Kaizen in manufacturing and office environment.





People in Purple
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Shivangi Page
Shivangi is an alumnus of St. Xaviers College Mumbai from where she graduated
in Sociology and completed her MPM from IndSearch Institute under Pune
University. She joined Thermax as a Management Trainee and did some path-
breaking work in Industrial Relations followed by a stint in Business HR before
heading Corporate HR. she has her expertise in Design and Conducting of the
Assessment / Development Centers as well as in Employee Engagement besides
being an outstanding training faculty. Shivangi is the Founder Member of Purple
HR Consulting.
Rajasi Lonkar
Rajasi is a graduate in Hotel Management from the University of Pune. Thereafter
she worked for a year in The Oberoi, Mumbai. Rajasi completed her MBA-HR from
the University of Pune in May 2013. She joined Purple as Associate Consultant and
provides effective support in the conduct of Company Diagnostic Study, HR
Process Reviews, and independently handles Data Analysis, Back end work


World Class Manufacturing















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Thank you
Exercise on Job Analysis