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8/8/2019 POM World Class Manufacturing
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WORLD CLASS MANUFACTURING
Presented by:
B. Pavana Harish
Soumya Ranjan Panda
Sadhana Mishra
Anish Rizwan
Viplav Vijay Choubey
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WORLD CLASS MANUFACTURING
It refers to the practice followed in a manufacturing
organizations, in order to consistently deliver
exceptional performance, frequently in excess of
expectations.
World Class Manufacturers are those that
demonstrate industry best practice
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Leaders in world class manufacturing
leader in manufacturingpractices
Toyota Motors
General Electric Boeing Corporation
Honeywell, Rockwell
NCR
ITT industries
Motorola
These companies haveset the trend s formanufacturing quality.
Other companies areadopting quality andimprovement toolsbeing used by theseorganizations
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Principles behind world class
manufacturing
Just in Time or Lean Manufacturing, the step by step
elimination of waste
total quality, Total quality is often these days called
Six Sigma
total preventative maintenance -unplanned
stoppages due to equipment failure are minimized.
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How to achieve world class
manufacturing
Develop the awareness of the need to make the
transition to World Class Manufacturing
Develop the ability to search for relevant tools and to
apply them effectively
Monitor progress so that an improvement program
can be systematically utilized
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Tools to measure and record process (1/2)
Critical SuccessFactor World
ClassManufacturing tool Measurement Indicators
Cost control Just-in-time logistics,
quality at source and SCM tools
Inventory holdings
Absence of defects and
rework
Cost of incoming
materialsQuality Statistical Process Control,
fool-proofing to prevent
errors, Pareto analysis of
types and causes of
production defects
Customer return rates
Internal reject, rework
and scrap rates
Supplier quality
performance
External flexibility Just-in-time logistics,
quality at source and supply
chain management tools
Time from customer
order to delivery
Delivery frequency and
reliability to customers
Delivery frequency and
reliability of suppliersIBA, Academic purposeonly
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Tools to measure and record process (2/2)Critical Success Factor World Class
Manufacturing tool
Measurement Indicators
Internal flexibility Cellular layouts, single unit
flow, production pulling,
kanban signaling system,
single-minute exchange of
dies for rapid machine
Machine changeover
times
Batch and lot sizes
Inventory levels
Throughput timeCapacity to change
(Human resource
development)
Multi-tasking, multi skilling,
quality circles,
kaizen groups, training,
incentive schemes.
Numeracy and literacy
levels
Labor/management
turnover levels
Absenteeism rates
Training expenditureand types of training
Employee development
Innovation capacity Concurrent engineering,
new product development
techniques
R&D expenditure
Proportion of sales from
new products
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Factors which can make a WCM
Organization(Team Work)
Flexibility
Discipline
Equality
TeamAutonomy
De-layeringManagement
CellOrganization
Leads toOwnership
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International benchmarking Benchmarking is the process of comparing organization's
practices with the best in class organization.
The purpose of this tool is to enhance productivity, Quality,
Customer satisfaction and reduction in cycle time or lead time
by comparing practices of that best class organization.
Recognized Standards:
ISO 9001:2008 (QMS) (Quality Management System)
ISO 14001:2004 (EMS) (Environmental Management System)
ISO 27001:2005 (ISMS) (Information Security Management System)
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Awards
Malcolm Baldrige National Quality Award this award is given
to those organizations, which perform best in the following
seven categories:
1. Leadership
2. Process Management
3. Customer & Market Focus
4. Strategic Planning
5. Workforce Focus6. Measurement, Analysis and Knowledge Management
7. Results
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Some models
Lean Manufacturing developed by Japanese is focusing onproviding best quality product to the customer, within theminimum possible time, on the targeted place with minimumwaste of material, labor, space and time
Total Productive Maintenance developed by Japanese is notmerely a maintenance tool, but it has unified operator andmaintenance person. They both are responsible for safe, cost
effective operation of machine or equipment
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THANK YOU