WCM

INTRODUCTION
CHRIS BAKER
GROUP MANUFACTURING EXCELLENCE CAPABILITIES
MANAGER
English, live in Manchester.
Joined Unilever in 1997.
2 Children.

Operational Background from

SUs.
Electrical Engineer by training.

Key Roles:-
Project Manager
Technical Manager
Operations Manager
Quality Improvement Project
What is WORLD CLASS
MANUFACTURING
World ?
Class Manufacturing
(WCM) is a structured and
integrated production system
that involves all site’s processes
and the entire organization from
top to shopfloor people.

WCM target is to
continuously improve
site’s performance
eliminating waste &
losses.
Management Safety
Commitment

Clarity of Cost
objectives Deployment

Route map to Focus

WCM Improvement
WCM Pillars

Allocation of
highly Autonomous
qualifed Activities
people

Commitment Professional
of the Maintenance
organization

Competence
of the Quality
organization

Logistics &
Time &
10 Technical Pillars

Customer
10 Managerial Pillar

Budget Service

Level of EEM & EPM

details

Level of People
expansion Development

Motivation of Environment
operators
 WCM is not….
….WCM is
 WCM is NOT WCM is
A project A program, a way of working

A toolkit of methods and tools Integrated production system

Restructuring program Continuous learning-improvement

A technical job for operators and program

engineers A leadership and management

Top-down OR bottom up program

An activity oriented program Top-down AND bottom-up approach

Cost cutting program A results oriented program

A safety-quality and productivity

improvement program

The Toyota style is not to create results by working hard.

It is a system that says there is no limit to people’s
creativity. People don’t go to Toyota to ‘work’ they go
5
there to ‘think’” - Taiichi Ohno
WCM – Pillar approach

7
steps

Pillar score

0-5

reactiv
e proactiv
preventi e
ve
 WCM – Pillar Approach
Model Area selection: most critical
Model Area
area, with highest losses for each specific Implementation
pillar

Safety = highest accidents/incidents

7 Steps
area Expansion
AM = highest BDs losses due to lack of 1
2
basic conditions Application of pillar

PM = highest BDs losses due to lack of 7 steps approach

maintenance in Model Area to

create knowledge
Other Areas
Extension
Extension in other areas 3
After reaching a certain step in the model
area, same approach is applied in other areas.

AM = after reaching step 3 in model area with

proved results team expand AM in the second
most critical area
 WCM Score: 0-100 points
World
Gold 85-
Class
70-84 100 pts
Silver pts

60-
Bronze
69 pts Be the WC leader
50- in Q, C and D in

Beginne business.

59 pts Achieve a ca. 50% cost

1-
rs substantial gains
in Q, C and D in
reduction

manufacturing
49 Establish the basic
competence.
4-5
pts
conditions for
25 – 40% cost
competitive
reduction
manufacturing
Years
10 – 20% cost 3 years
reduction

2 years
1 year
WCM Ambition
 Growing skills and Capability – “Zero Gaps”

 Zero Accident & Zero First Aid

 Zero machine breakdown

 Zero quality defects

 Zero customer claims

 Zero minor stoppages

 Zero waste & losses

 WCM Audits Completed
Last Score # Audits
38
37

31 31

25
24

20
17
14 14
13 13
11 11
9 9 9
8 8
7 7
6 6 6
5 5
4
4 4 4 4 4
3 3
2
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Increasing the speed…
… to meet business
opportunities
TECHNICAL SKILLS UPGRADE IS
PIVOTAL TO ELIMINATE LOSSES AND
WASTE IN OUR LINES
Top Losses (WCM sites)