World Class Manufacturing

PGDM- VI-TH SEMESTER WORLD CLASS MANUFACTURING SYLLABUS

UNIT-I : (WHAT IS WORLD CLASS MANUFACTURING) MEANING OF WORLD CLASS MANUFACTURING, DIFFERENT MODELS OF WORLD CLASS MANUFACTURING: GUNNS MODEL, MASKELLS MODEL, AMERICAS BEST PLANT MODEL, MALCOM BALDRIDGE QUALITY AWARD. UNIT-II : (PRINCIPLES AND PRACTICES OF WORLD CLASS MANUFACTURING) CUSTOMER FOCUS, TOTAL QUALITY MANAGEMENT, LEAN PRODUCTION, TOTAL EMPLOYEE INVOLVEMENT, CONTINUOUS IMPROVEMENT UNIT-III : (TOTAL QUALITY MANAGEMENT) FOUR ERAS OF QUALITY, QUALITY IMPROVEMENT TECHNIQUES, DESIGNING FOR ZERO DEFECT MANUFACTURE, SPC, PROCESS CAPABILITY STUDIES, SIX SIGMA UNIT-IV : (JUST-IN-TIME) ATTACKING WASTE, REDUCING LEADTIME,REDUCING STEP TIMES, REDUCING INVENTORY, IMPROVING LABOUR FLEXIBILITY, IMPROVING SUPPLIERS PERFORMANCE, DESIGNING FOR MANUFACTURING EFFICIENCY, THE KANBAN SYSTEM, RELIABILITY CENTRED MAINTENANCE UNIT-V: (LEAN PRODUCTION) WASTE ELIMINATION IN MANUFACTURING (7 OLD MUDAS AND 7 NEW NUDA), FLEXIBLE MANUFACTURING SYSTEM, RAPID PROTOTYPING, LEAN PRODUCTION TOOLS, POKAYOKE, SMED UNIT-VI: (TOTAL EMPLOYEE INVOLVEMENT) EFFECTIVE TEAM WORK, STRATEGIC IMPROVEMENT TEAMS, LOCAL IMPROVEMENT TEAMS, QUALITY CIRCLES, PERSONAL COMMITMENT, TRAINING & DEVELOPMENT, REWARDING SUCCESS UNIT-VII: (WORLD CLASS INFORMATION SYSTEM) INFORMATION NEEDS, INFORMATION MANAGEMENT TOOLS UNIT-VIII: (MANAGING WORLD CLASS PERFORMANCE ) QUALITY PERFORMANCE, CYCLE TIME, DELIVERY PERFORMANCE, CUSTOMER SERVICE, FINANCIAL PERFORMANCE, THE BALANCE SCORE CARD UNIT-IX MANAGING THE CHANGE

OBJECTIVE
TO UNDERSTAND THE SPECIALITY OF WORLD CLASS MANUFACTURING TO DEVELOP HOW A NORMAL MANUFACTURING SYSTEM MAY BE CONVERTED INTO A WORLD CLASS MANUFACTURING TO HAVE AN IDEA OF USE OF DIFFERENT TOOLS OF WCM TO MAKE YOURSELF PREPARED FOR WORKING IN A WCM ENVIRONMENT

Definition
World Class Manufacturing is a different set of concepts, principles, policies and techniques for managing and operating a manufacturing company. It is driven by the results achieved by the Japanese manufacturing resurgence following World War II, and adapts many of the ideas used by the Japanese in automotive, electronics and steel companies to gain a competitive edge. It primarily focuses on continual improvement in quality, cost, lead time, flexibility and customer service.

Definition
World Class Manufacturing is a process-driven approach where implementations usually involve the following philosophies and techniques:

Make-to-order Streamlined flow Small lot sizes Families of parts Doing it right the first time Cellular manufacturing Total preventive maintenance

Definition
MAKE TO ORDER Manufacturing or assembly process geared to satisfy customer-requirements only upon receiving a customer's order. It may require the combination of standard and custommade parts, if it requires only standard parts it is called assemble to order process

Definition
Small Lot sizes Small lot production (ideally one piece) is an important component of many Lean Manufacturing strategies. Lot size directly affects inventory and scheduling. Other effects are less obvious but equally important. Small lots reduce variability in the system and smooth production. Small lots also enhance quality in many ways.

Definition
World Class Manufacturing is a process-driven approach where implementations usually involve the following philosophies and techniques:

Quick changeover Zero Defects Just-in-time Variability reduction High employee involvement Cross functional teams Multi-skilled employees Visual signaling Statistical process control

Definition
Companies engaging in World Class Manufacturing strategies focus on improving operations, strive to eliminate waste and create lean organizations. This often results in higher productivity. But these companies also focus on speed of total throughput from order capture through delivery setting new standards for delivery without the heavy dependence on inventory. Sequential methods of performing work are being replaced with concurrent methods to compress time, and functional and hierarchical divisions of duties are being replaced by team-driven activities.