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Submitted by: Sonal Priya Roll No:0914340052

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

Product quality right first time, every time

Focus Areas:

S: Safety : to eliminate accident


Q: Quality : to way to reach the best production quality in worldwide C: Cost : Reduce production cost by reducing waste and loss
D: Delivery : Reduce delivery time E: Environment : Reduce environmental accidents to zero and reduce negative environmental effects

Being the best

Delighting the customer?

Being the lowest cost producer

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

World Class Manufacturing Approach

What is the Problem? Where? What is the priority? Evaluation of Results

Waste/ Loss Analysis


Right Methods
Benefit / Cost

Improvement and Expansion

Implementation
Implementation with Discipline

Participation of all employees

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

effective Flexibility Innovation

WCM Basic Structure and Objectives

Safety Quality Cost Deployment


Method & Standards
Total Quality Control (TQC) Quality Improving

Workplace Organizatio n

Maintenanc e

Logistic

Total Industrial Eng. (TIE)

Total Productive Main. (TPM) Technical Efficiency

Just in Time (JIT)

Focus

Productivite

Service Level

Target

0 Defect

0 Waste

0 Breakdown

0 Stock

0 Accident

World Class Manufacturing Structure

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 WCM Road Map

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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