Unit I: Introduction to World-Class Manufacturing - Introduction, product development process, process mapping, Information Age and its impacts, Competition, advances in manufacturing technology. Introduction to World-Class Manufacturing World-Class manufacturing was the term introduced for referring to the goal of achieving and/or sustaining World-Class competitiveness through manufacturing excellence, attained through best practices. World Class Manufacturing is a set of concepts, policies, techniques, and principles for operating_and managing a manufacturing company. The concept of World Class Manufacturing is based on the positive results achieved by Japanese Manufacturing companies after World War I, These manufacturing. processes focus on continual improvement in quality, cost, lead time, flexibility, and customer service. ie. World dass 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, clectronic and stel industry World Class Manufacturing is a processdriven approach that general following philosophies and techniques: involves implementing the + Make-to-order 4 Streamlined flow + Small lot sizes + Families of parts + Doing it right the first time + Cellular manufacturing ‘+ Total preventive maintenance + Quick changeover + Zero Defects + Justin-time + Variability reduction + Employee involvement ‘+ Cross functional teams, ‘+ Multi-skilled employees + Visual signals 4+ Statistical process control ‘To achieve world-class status, companies must change procedures and concepts, which lead to reconstructing ‘relationships with suppliers, purchasers, producers, and customers.Y 10pillars of world class manufacturing 10 technical pillars of World Class ManufacturingSAF Safety oo Cost Deployment A Focused Improvement AA ‘Autonomous ‘Activities mM Professional Maintenance we Quilty Contel LOG Logistics & Castomer Service FEM Early Equipment Management PM. Early Product Management Continuous improvement of safety Analysis ofthe losses and costs (loses within the costs) Priorities of actions to ‘management the loss identtied by the cost deployment Continuous improvement of plant and workplace Continuous improvement of downtime and Falures ‘Continuous improvement of customers’ needs Optimization of stocks Optimization of installation time and costs and ‘optimization of features of new products ‘To reduce drastically the numberof accidents ‘To develop a culture of prevention To improve the ergonomics ofthe workplace ‘To develop specific professional skills ‘To identify scientifically andl systematically the m: produiction-logistics business ‘To quantify the potential economic benefits and expected ‘To adress the resources and commitment to managerial tasks with grestest potential tems of loss in the system ‘To reduce drastically the most important losses present in the system manufacturing plant, eliminating inificiencies ‘To climinate non-value-added activities, in order to increase the competitiveness of the cost of the prodct ‘To develop specific professional skills of problem solving Iti constituted by two pillars AM Auronomous Maintenance, Wis used to imrove the overall cffciency ofthe production system through maintenance policies through the conductors (equipment specialists). WO Workplace Organization. Te is develops to determine an impcovemert inthe workplace, because oft the materials and equipment are degrade; in particular because inthe process there are many losses (MUDA)to remove. "To increase the efficiency of the machines using failure analysis techniques. ‘To facilitate the cooperation between conductors (equipment specialists) and maintaa (maintenance people) 10 reach zero breakdowns. To ensure quality products, ‘To reduce non-compliance To increase the skills ofthe employees. ‘To reduce significantly the levels of stocks. ‘To minimize the material handling, even with direct deliveries ftom suppliers tothe assembly line, ‘To putin place new plants as scheduled, ‘To ensure a rap start-up and stable ‘To rece the Life Cycle Cost (LCC). ‘To design systems easily maintained and inspected.wo Continuous improvement o¢ TEU, through a stud eye of trinng, soret ills and abilities foreach souuoe Poole, Sie Sale pcempbrpeaae clop the roles of maintenance workers, technolo ‘specialists such as major Compo, «| Some Teabeie k aSa HR A, ESR TC TY nae Eve Stiwos improvement | comply whe requirements dst fenton managonen — : Todovlopan cary clue and ralice be energy css an le, ‘There are seven keys to becoming a world-class manufacturer: Reduce lead times Speed time-to-market ‘Streamline outsourcing processes Cut operations costs Exceed customer expectations Manage the global enterprise Improve business performance visibility Companies using World Class Manufacturing strategies focus on improving operations. eliminating waste, and creating Lean organizations, which often results in higher productivity. These companies also focus on setting new standards for speed from order capture through delivery without the heavy dependence on inventory. Sequential methods of performing work are being replaced with concurrent methods to compress and functional and hierarchical divisions of duties are being replaced by team- Principles of World Class Manufacturing ‘There are three main principles, which drive world-class manufacturing. + Implementation of justin time and fean management leads to reduction in wastage thereby reduction in cost + Implementation oftotal quality management leads to reduction of defects and encourages zero tolerance towards defects. + Implementation of total preventive maintenance leads 10 ‘mechanical failure > Aspects of World Class Manufacturing The main aspects of the world-class manufacturing are as follows: + Industsial culture area + Markevelient area + Produet development area + Operations area + E-Performance area > Characteristics of world class organizations Customer service, Quality control and assut Research and development! new product development Acquiring new technologies Innovation Team-based approach (adopting and using effectively) Best practices (study and use of) ‘Manpower planning 9. Environmentally sound practices 10. Business partnerships and alliances 11. Reengineering of processes 12, Mergers and acquisitions 13, Outsourcing and contracting ance, ny stoppage of production through14. Reliance on consulting services 15, Political lobbying > How to make an organization world class? Worker productivity (improvement) 2. Employee training and development 3. Open communication between management and employees 4, Employee benefits and perquisites 5 Codes of workplace conduct 6, Conflict resolution 7. Employee satisfaction 8, Flextime arrangements 9, Management-employee-union relations 10, Child care Product development process (PDP) In business and engineering, new product development (NPD) covers the complete process of bringing a new product to market. A central aspect of NPD is product design, along with various business considerations. New product development is described broadly as the transformation of a market opportunity into a product available for sale, Ihe product can be tangible (something physical which one can touch) or intangible (ike service, experience, or belie), though sometimes services and other processes are distinguished from “products.” NPD requires an understanding of customer needs and wants, the competitive environment, and the nature of the market, Cost, time and quality are the main variables that drive customer needs. Aiming at these three variables, innovative companies develop continuous practices and strategies to better satisfy customer requirements and to increase their own market share by a regular development of new products ‘There are many uncertainties and challenges which companies must face throughout the process. The use of best_practices and the elimination of bartiers to communication are the main concerns for the management of the NPD. STEPS: 1. Idea Generation and Sereening (brainstorming and coming up with innovative new ideas. See generating ideas for new products and services. Filtering out any ideas not worth taking forward, See screening new product or service idea.) 2. Concept Development and Testing (considering specifications such as technical feasibility, product design and market potential. See researching new product and service ideas.) 3. Marketing Strategy (ensuring your ideas fit into your business’ strategic plans and determining the demand, the costs and the profit margin, 4. Business Analysis 5. Product Development (creating a prototype product or pilot service. See concept development and testing.)6. Test marketing (modilying the product or service acconding to customer, manufacturer and support organizations’ feedback. This involves deciding the best timing and process for piloting your new product or service. See how to fest the market.) 7. Commerciatization (determining the pricing for your product or service and finalizing marketing plans. See pricing vour proposed service or product. A det introduction to market.) sd Iaunch plan can help ensure smooth + Idea Generation Idea Sc [+ Iden Screening wy ce ot Te 2) | + Concept Testing vy eg [> ttainess Anatyais ry W) | » Product Develop: SY) | = Test Marketing ee + Commercialisation + Review of Market Performance €¢ 1. Tdea generation ‘The fist step in new-product development is idea generation. New ideas can be generated by: + Conducting marketing research to find out the consumers’ needs and wants. + Inviting suggestions from consumers, + Inviting suggestions from employees. + Brainstorming suggestions for new-product ideas. + Searching in different markets viz., national and intemational markets for new-product ideas + Getting feedback from agents or dealers about services offered by competitors + Smdying the new products ofthe competitors. 2. Idea sereening Most companies have a “Idea Committee." This committee studies all the ideas very carefully. They select the ‘good ideas and reject the bad ideas. Before selecting ot re ting an idea, the following questions are considered or asked: + Ist necessary to introduce a new product? + Can the existing plant and machinery produce the new product? + Can the existing marketing network sell the new product? ‘+ When can the new product break even?If the answers to these questions are positive, then the idea of a new-product development is selected else it is rejected. This step is necessary to avoid product failure. 3. Concept testing Concept testing is done after idea screening. Itis different from test marketing. In this stage of concept testing, the company finds out: ‘+ Whether the consumers understand the product idea or not? + Whether the consumers nced the new proxtuct or not ‘+ Whether the consumers will accept the product or not? Here, a small group of consumers is selected. They are given full information about the new product, Then they are asked what they feel about the new product. They are asked whether they like the new product or not So, concept testing is done to find out the consumers’ reactions towards the new product. IF most of the ‘consumers like the product, then business analysis is done. 4, Business analysis Busiuess aualysis is @ very important step ius uew-product developusent. Here, a detailed busiviess analysis is done. The company finds out whether the new product is commercially profitable or not. Under business analysis, the company finds out. ‘+ Whether the new product is commercially profitable or not? ‘+ What will be the cost of the new product? + Is there any demand for the new product? ‘+ Whether this demand is regular or seasonal”? + Are there any competitors of the new product? + How the total sales of the new product be? + What will be the expenses on advertising, sales promotion, etc.? + How much profit the new product will earn? + So, the company studies the new product from the business point of view. If the new product is profitable, it will be accepted else it will be rejected. 5. Product development At this stage, the company has decided to introduce the new product in the market. It will take all necessary steps to produce and distribute the new product. The production department will make plans to produce the product. The marketing department will make plans to distribute the product. The finance department will 8provide the finance for introducing the new product. The advertising department will plan the advertisements for the now product. However, all this is done as a small scale for Test Marketing, 6. Test marketing ‘Test marketing means to introduce the new product on a very small scale in a very small market. If the new product is successful in this market, then itis introduced on a large scale. However, if the product fails in the test market, then the company finds out the reasons for its failure, It makes necessary changes in the new product and introduces it again in a small market. If the new product fails again the company will reject it. Test marketing reduces the risk of large-scale marketing. It is a safety device. It is very time-consuming, It ust be done especially for costly products. 7. Commercialization Ifthe test marketing is successful, then the company introduces the new product on a large scale, say all over the country. The company makes a large investment in the new product. It produces and distributes the new product on a huge scale. It advertises the new product on the mass media like TV, Radio, Newspapers and Magazines, ete 8. Review of market performance ‘The company must review the marketing performance of the new product. 1 must answer the following questions: + Is the new produet accepted by the consumers? + Are the demand, sales and profits high? ‘+ Are the consumers satisfied with the after-sales-servi + Are the middlemen happy with their commission? + Are the marketing staffs happy with their income from the new product? ‘+ Is the Marketing manager changing the marketing mix according to the changes in the environment? + Are the competitors introducing a similar new product in the market? The company must continuously monitor the performance of the new product. They must make necessary changes in their marketing plans and strategies else the product will fail. Process mapping A process map is a planning and management tool that visually describes the flow of work. Using process mapping soltware, process maps show a series of events that produce an end result. A process map is also called a flowchart, process flowchart, process chart, functional process chart, functional flowchart, process ‘model, workflow diagram, business flow diagram or process flow diagram. It shows who and what is involved 9in a process and can be used in any business or organization and can re improved, Process mapping is the act of creating a workflow diagram with the goal of gaining a clearer understanding of how a process and its parallel processes work With process maps, employees-especially in upper-level management, can easily gain an overview of how processes are carried out, how they can be improved or constrained, and how many of the steps taken are necessary to drive the process to its end. areas where a process should be i.e. Process mapping is used (0 visually demonstrate all the steps and decisions in a particular process. A process map or flowchart describes the flow of materials and information, displays the tasks associated with a process, shows the decisions that need to be made along the chain and shows the essential relationships between the process steps, Y Purpose of process mapping ‘The purpose of process mapping is for organizations and businesses to improve efficiency. Process maps provide insight into a process, help teams brainstorm ideas for process improvement, increase communication and provide process documentation, Process mapping will identify bottlenecks, repetition and delays. They help to define process boundaries, process ownership, process responsibilities and effectiveness measures or process meties Understanding processes ‘One of the purposes of process mapping is 10 gain better understanding ofa process. The flowchart below is a 200d example of using process mapping to understand and improve a process. In this chart, the process is ‘making pasta. Even though this is a very simplified process map example, many parts of business use similar diagrams to understand processes and improve process efficiency, such as operations, finance, supply chain, sales, marketing and accounting. 10f 1 | 2 t | Benefits of process mapping Process mapping spotlights waste, streamlines work processes and builds understanding. Process mapping, allows you to visually communicate the important details of a process rather than writing extensive directions. ¥ Flowcharts and process maps are used to: ‘+ Increase understanding of a process ‘+ Analyze how a process could be improved ‘+ Show others how a process is done ‘+ Improve communication between individuals engaged in the same process ‘+ Provide process documentation + Plan projects ¥ Process maps can save time and simplify projects because they: ‘© Create and speed up the project design ‘+ Provide effective visual communication of ideas, information and data ‘+ Help with problem solving and decision making ‘+ Identify problems and possible solutions ‘+ Can be built quickly and economically ‘+ Show processes broken dawn into steps and use symbols that are easy to fallow ‘+ Show detailed connections and sequences ‘+ Show an entire process from the beginning to the end Process maps help you to understand the important characteristics of a process, allowing you to produce helpful data to use in problem solving. Process maps let you strategically ask important questions that help ‘you improve any proces u¥ Types of process mapping Process mapping is about communicating your process to others. You process maps, The most common process map types include: build stronger understanding with ‘+ Activity Process Map: represents value added and non-value added activities in a process ‘+ Detailed Process Map: provides a much more detailed look at each step in the process + Document Map: documents are the inputs and outputs in a process + High-Level Process Map: high-level representation of a process involving interactions between Supplier, Input, Process, Output, Customer (SIPOC) + Rendered Process Map: represents current state and/or future state proc process improvement ‘+ Swimlane (or Cross-functional) Map: separates out the sub-process responsibilities in the process + Value-Added Chain Diagram: unconnected boxes that represent a very simplified version of a process for quick understanding + Value Stream Map: a lean-management technique that analyzes and improves processes needed (© make a product or provide a service to a customer. ‘+ Work Flow Diagram: a work process shown in “flow” format; doesn’t utilize Unified Modeling Language (UML) symbols. 's to show areas for ‘+ Process mapping symbols Key elements of process mapping include actions, activity steps, decision points, functions, inputvoutputs, people involved, process measurements and time required. Basic symbols are used in a process map to describe key process elements. Each process element is represented by a specific symbol such as an arrow, circle, diamond, box, oval or rectangle. These symbols come from the Unified Modeling Language or UML, which is an international standard for drawing process maps. | Predefined ~ _Qa>—- 2¥- Business process mapping In business, a process is a group of interrelated tasks that happen as a result of an event, These tasks produce a desired result for the customer. Process mapping can be used in many areas of business: business process improvement, business process redesign, reengineering, taining, quality improvement, simulation, information technology, work ‘measurement, documentation, process analysis, operational process design, process integration, acquisitions, mergers and selling business operations, Business process mapping can also be helpful for complying with manufacturing and service industry regulations, such asthe common ISO 9000 (International Organization for Standardization) or ISO 9001. Y How to create a process map Process mapping was become streamlined because of software that provides a better understanding of processes, Process maps can be created in common programs like Microsoft Word, PowerPoint or Excel, but there are other programs more customized to creating a process map. Process mapping is about communicating your process to others so that you achieve your management objectives. Knowing how to map 1a process will help you build stronger communication and understanding in your organization Step 1: Identify the problem ‘What is the process that needs to be visualized? Type its ttle atthe top of the document, Step 2: Brainstorm activities involved AU this point, sequencing the steps isn’t important, but it may help you to remember the steps needed for your process, Decide what level of detail to include. Determine who does what and when it is done. ‘Step 3: Figure out boundaries ‘Where or when does the process start? ‘Where or when does the process stop? Step 4: Determine and sequence the steps I's helpfal to have a verb begin the description You can show either the general flow or every detailed action or decision, Step 5: Draw basic flowchart symbols Each clement in a process map is represented by a specific flowchart symbol ‘Ovals show the beginning ofa process or the stopping of a process. Rectangles show an operation or activity that needs to be done. Arrows represent the flow of direction. Diamonds show a point where a decision must be made. Arrows coming out of a diamond are usually labeled yes oF no. Only one arrow comes out of an activity box. If more than is needed, you should probably use a decision diamond. A parallelogram shows inputs or outputs Step 6: Finalize the process flowchart 13Review the flowchart with others stakeholders (team member, workers, supervisors, suppliers, customers, etc.) for consensus. Make sure you've included important chart information like a title and date, which will make it easy to reference, Helpful questions to ask: Is the process being run how it should? Will team members follow the charted process? Is everyone in agreement with the process map flow? Is anything redundant? Are any steps missing? Proces maps provide valuable insights into how a businesses or an organization can improve processes. ‘When important information is presented visually, it increases understanding and collaboration for any project. Information Age and its impacts Development of Information Age American futurist Alvin Toffler has described three periods of economic evolution, 1, The agricultural age from 8000BC to mid 18" century 2. The industrial age which lasted until the late twentieth century 3. He information age that began in 1960s Information age is driven by knowledge workers and information technology. Knowledge workers are those ‘who work with information rather than producing goods. After World War 2 the capital for business became enormous and the focus shifted (0 information than being product oriented. Information thus became the source for knowledge as well as the medium to apply knowledge. ‘Emerging Business Trends in Information Age: In industrial age wealth was created by manufacturing. The process of making things was changed due 10 technology it reached its peak from 1960-80, In this information age, wealth was created by manufacturing .the process of making things was changed to technology. Business challenges of Information age: Managing uncertainty Understanding globalization of business Operating environment of information age business Business process orientation Links to customers and suppliers Customer segmentation Global scale Managing innovation Knowledge workers 14The Information Age (also known as the Computer Age, Digital Age, or New Media Age) isa period in human history characterized by the shift from treditional industry that the industrial revolution brought through industrialization, to an economy based on information computerization. The onset of the Information Age is associated with the Digital Revolution, just as the Industrial Revolution marked the onset of the Industrial Age. During the information age, the phenomenon is that the digital industry creates a knowledge-based society surrounded by a high-tech global economy that spans over its influence on how the manufacturing throughput and the service sector operate in an efficent and convenient way. In a commercialized society, the information industry is able to allow individuals to explore their personalized needs, therefore simplifying the procedure of making decisions for transactions and significantly lowering costs for both the producers ‘and buyers. This is accepted overwhelmingly by participants throughout the entire economic activities for efficacy purposes, and new economic incentives would then be indigenously encouraged, such as the knowledge economy. The Information Age formed by capitalizing on the computer microminiaturization advances, with a transition spanning from the advent of the personal computer in the late 1970s, to the Internet's reaching a critical mass in the early 1990s, and the adoption of such technology by the public in the two decades after 1990, This evolution of technology in daily life, as well as of educational life style, the Information Age has allowed rapid global communications and networking to shape modern society, The impact of digital age on the social life of the society today is connected with one's position in the society, his social class and also his social background, nowadays; there are so many changes in the social aspect of ‘our lives. A very good example of this is festival, changes in tradition and also in the mood of dressing, allthis became possible because of the impact of digital age we have today. If we look around us today, it’s hard to find a person that has not added anything new to his traditional attires , what | mean here is, for instance, for the Hausa’s and also the Fulani’, there were not know for wearing jeans and tops, but now it has become a ‘common thing based on socialization, Before, many do not believe in going to school especially the Fulani’, they only believe in rearing cartle's while the women among them are to stay at home, but now, everyone \wants to be in school, ilteracy is darkness, people don't believe in staying at home doing nothing anymore, for at least even when they lack the opportunity or don’t have the means of going school or seeking for job ‘opportunity, they will prepare engaging themselves in a small business just for them to earn something for a living, There are so many changes due to the impact digital age on the social lfe of our societies today. Y Impact of the Information Age The Information Age moved society from an industry-based economy to an information-based economy, It has generated research, work, commerce and new forms of entertainment and has given most of the world access to information, The Internet and its subsequent developments are prime examples of technology to stem from the Information Age 15‘The Internet shaped modem society by creating fast global communication and networking to allow research, ‘work and technology to grow faster than ever. As of 2014, 180 countries have some form of Internet access. ‘The Intemet was created by the Defense Advanced Research Projects Agency; its initial applications were file transfers and email. Technologies developed subsequently impacted the economy with many businesses and industries being significantly changed. For example, the costs of printing a book on paper and shipping it are drastically higher than the costs of duplicating the book on a computer and sending it through the Internet. ‘The workforce also saw major changes during the Information Age with simple tasks becoming automated: as a result, more workers were forced to compete in the global job market, Some of the innovations that resulted from the Information Age are the transistor, the Internet, email, video game consoles, personal computers, laptops, cell phones, digital cameras, wireless networking, global positioning satellites and smart phones. ¥ Advantages Of Information Technology Every day, people use technology in new ways. Computers are increasingly affordable; they c to be more powerful as information-processing tools as well as easier 10 use, Some of the advantages of information technology include: Globalization - IT hs not only brought the world closer together, but it as allowed the world’s economy to become a single interdependent system. This means that we can not only share information quickly and efficiently, but we can also bring down barriers of linguistic and geographic boundaries and countries are able to shares ideas and informati ‘with each other. Communication - With the help of information technology, communication has also become cheaper, quicker, and ‘more eflicient. The internet has also opened up face to face direct communication from different parts of the world thanks to the helps of video conferencing. Many collaboration platforms have been builtin acldition to face to face call via mobile devices like iphone Cost effectiveness - Information technology has helped to computerize the business process thus streamlining businesses to make them extremely cost effective money making machines. This in turn increases productivity which ultimately gives rise to profits that means better pay and less strenuous working conditions. ‘More time - IT has made it possible for businesses to be open 24 x7 all over the globe. This means that a business can bbe open anytime anywhere, making purchases from different countries easier and more convenient. Creation of new jobs - Probably the best advantage of information technology is the creation of new and interesting jobs. Computer programmers, Systems analyzers, Hardware and Software developers and Web designers are just some ‘ofthe many new employment opportunities ereated with the help of IT. ¥ Inconveniences Of Information Technology ‘Some disadvantages of information technology include: 161. Unemployment - While information technology may have streamlined the business process it has also created job redundancies, downsizing and outsourcing. This means that a lot of lower and middle level jobs have been done away with causing more people to become unemployed 2. Privacy ~ Though information technology may have made communication quicker, easier and more convenient, it has also bought along privacy issues. From cell phone signal interceptions to email hacking people are now worried about their once private information becoming public knowledge. 3. Lack of job security - Industry experts believe that the Internet has made job security a big issue as since technology keeps on changing with or she wishes for their job to be secure. ch day. This means that one has to be in a constant leaming mode, if he 4, Dominant culture - While information technology may have made the world a glabal village, it has also contributed to one culture dominating another weaker one. For example it is now argued that US influences hhow most young teenagers all over the world now act, dress and behave. Languages too have become overshadowed, with English becoming the primary mode of communieation for business and everything else. Advances in Manufacturing Technology Six recent advances in automation that are making big waves in the manufacturing industry: 1. Cloud storage for wireless data One of the greatest advances in automation is one that stands to benefit every industry is cloud storage. Cloud storage allows you to store all data wirelessly. All data from almost every machine can be automatically uploaded, ensuring that all information is backed up over a wireless network. Additionally, in case of any computer crashes, all of your data is completely sale, accessible from any computer and waiting to be recovered from the cloud 2. Diode lasers for creating “invisible” seams Diode lasers are adding greater efficiency in assembly processes in the automotive industry. Audi, the German car manufacturer, recently implemented robot controlled 13-kW diode lasers in their Ingolstadt factory, This allowed the company to create an “invisible” weld on the car shell, providing additional structural security throughout the v7By programming these diode lasers, Audi is coupling automation with a host of other advanced processes, such as welding and bonding. As a result, the manufacturer is reducing car weight, production time, and nergy costs due to regenerative braking in conveyor and lift systems 3.3D printing in manufacturing for finished components 3D printing is one of the biggest recent advances in manufacturing and automation. Although the technology hhas been around since the 1980s, achines were previously 100 large and the process was too slow for ‘widespread adoption. Today, however, 3D printers have become so developed that these machines are used to produce finished parts. These machines now have the capability for improved accuracy and capacities for increased sizes and production runs. As a result, they are being adopted into processes throughout industries. The military, for example, conjectures that it may be able to print replacement parts in the battlefield. ‘The advantages of automated 3D printing are many. It allows much more affordable manufacture of complex, highly customized, and efficient designs—3D printed products can be lighter, stronger, and require less assembly. One machine can be responsible for a number of product lines, with production lines of as many or as few units as needed. 3D printers additionally allow for point-of-assembly or point-of-consumption printing. They present a lower barrier of entry to manufacturing, and open up a number of new supply et ‘opportunities. 4. Extremely small machines for nonmanufacturing Nano-manufacturing—the manufacture of material on a molecular or even atomic level—has been recently gaining steam. It is expected to play a future role in the production of items such as high-efficiency solar cells and batteries. ‘Nano-manufacturing is most promising for nonmanufacturing purposes such as biosystem-based medical tions. As applica ensor inside your body, for instance, could help your doctor monitor eancer levels, Future ‘generations of electronics and computing devices may also heavily rely on nonmanufacturing, 5. 24-Hour manufacturing operations 18Continuous, hour manufacturing operations have come a long way in current years. Industrial robots can operate 24 hours a day, seven days a week, performing repeatable processes. The greatest advance in today's automated 24-hour machines the increasingly fine precision they can achieve, These machines can now be accurate to hundredihs of a Globally coordinated R & D ‘Manufacturing challenges of Information age: ‘+ Time based competition + Managing knowledge vyvvyy 19Problems in manufacturing industry + Problems ofco ordination + Need for control + Fragmented information structure + Insuificient processability of available information Gaining competitive advantage through WCM To achieve excellence in manufacturing, an organi 1. Through put should go up jon need to keep in mind five goals: 2. Inventory should come down 3. Operating expenses should come down 4, Cyele time shoukd come down 5. Yield should go up American manufacturing dominated the world in 1940s but since South progressed a long way giving America a tough competition because of: 1, Newer plants and equipment Reinvested in new plant and equipment Workers had low wage rates ‘Young generation had keen interest for a career in manufacturing Beucluarhed eit pesfoumaice with wuumpetiors Top management had a manufacturing background, Manufacturing excellence through value added manufacturing + Value added manufacturing- eliminating wastes suggested by Hall 1987. Three overlapping categories of work Total quality control Just in time Total people involvement 20