OPERATIONS ASSIGNMENT

Sukanya SOM
Surbhi sthapak
Tamanna
tahoor khan
yash desai
 WORLD CLASS MANUFACTURING
PRINCIPLES

World class manufacturing is a collection of concepts, which set standard for

production and manufacturing for another organization to follow.
The system is based on a systematic reduction of all types of loss and waste through
the contribution of everyone and the rigorous use of methods and standards.
World Class Manufacturing principles apply to all aspects of plant organization.
World Class Manufacturing (WCM) was born of the collaboration between Fiat and the
best European and Japanese experts, with the aim to enhance the production
standard to a recognized world standard.
Care for the Environment is one of the pillars of the system.
Environmental management system specifies actions geared to the reduction of the
environmental impact of manufacturing activities, both in order to ensure compliance
with the applicable regulations and in order to prevent the waste of energy and
natural resources
WORLD CLASS MANUFACTURING PRINCIPLES
World Class Safety is the foundation of World Class performance.
WCM Leaders have a passion for standards.
In a World Class Company, the voice of the customer can be heard in the plant
WCM does not accept losses. Zero accidents, ZERO service & quality defects, ZERO inventory, NObreakdowns)
A rigorous application of WCM methods guarantees the elimination of losses
In a World Class plant all abnormalities are immediately visible (Dust & contamination free, tracking, control
charts …)
WCM takes place in the workplace, not in the office
WCM is most effectively learnt by practicing the techniques with the plant teams

The power of WCM comes from the involvement of people

World Class companies create the energy for crisis times.
Lean Manufacturing
Management philosophy derived from TPS

Systematic method Centered on making obvious what adds value to the

customer by elimination of
•waste (MUDA) withing the manufacturing system.
•Waste created through overburden (MURI).
•Waste created through unevenness in work loads (MURA).

Characteristics Goals
Benefits •Zero breakdown
•Customer
•Customer satisfaction •Zero delays
driven
•Profitability •Zero inventory
•Profit driven
•Team based •Greater control •Zero Accidents
•Zero Paper work

 Effects of Implementing Single Minute

Exchange of Die (SMED):
SMED increases machine work rates from reduced setup times even if number of changeovers
increases
It eliminates setup errors while allowing trial runs to reduce defect rates
Improved quality from fully regulated operating conditions in advance
Increased safety from simpler setups
Simplified housekeeping from fewer tools and better organization
Stockless production drives a company’s capital turnover rates
Reduction in footprint of processes will reduce inventory, thereby freeing workshop space
Productivity increases over time
SMED lowers set up and other expense
Skill requirements are lower since changes are now designed into the process rather than a
matter of skilled judgement
Elimination of unusable stock from model changeovers and demand estimate errors
Goods are not lost through deterioration
Ability to mix production gives flexibility and further inventory reductions as well as opening the
door to revolutionized production methods
SMED
Single-minute exchange of die is the process of trying to make changeovers as fast as
possible. Quickly changing a process so that it can go from making one product to making
another helps reduce lead times and inventories and facilitate one -piece flow production. It
was first introduced by Shigeo Shingo.

Implementing Single Minute Exchange of Die (SMED)

Separate internal from external setup operations
Convert internal to external setup
Standardize function, not shape
Use functional clamps or eliminate fasteners altogether
Use intermediate jigs
Adopt parallel operations
Eliminate adjustments
Mechanization
Six Sigma
•Six Sigma is a disciplined, data-driven approach and
methodology for eliminating defects (driving toward six
standard deviations between the mean and the nearest
specification limit) in any process – from manufacturing to
transactional and from product to service.
•To achieve Six Sigma — statistically — a process must not
produce more than 3.4 defects per million opportunities.
•The fundamental objective of the Six Sigma methodology is
the implementation of a measurement-based strategy that
focuses on process improvement and variation reduction.
·A Six Sigma defect is defined as anything outside of customer
specifications.
·A Six Sigma opportunity is then the total quantity of chances
for a defect.
The fundamental objective of the Six
Sigma methodology is the implementation
of a measurement-based strategy that
focuses on process improvement and
variation reduction, This is accomplished
through the use of Six Sigma
methodologies: DMAIC .
The Six Sigma DMAIC process (define,
measure, analyze, improve, control) is an
improvement system for existing
processes falling below specification and
looking for incremental improvement
 3. A. Simile

A simile is an indirect comparison of two unlike

objects using the words "like" or "as". In this
sentence, the laughter of the witch is being
compared to nails on a chalkboard.

It is not an example of alliteration, which is the

repetition of consonant sounds.

LET'S CHECK It is not an oxymoron, because it doesn't

YOUR feature two contradictory terms side by side.

KNOWLEDGE! It is not an example of litotes, because it does

not express an understatement.
WHAT IS TOTAL PRODUCTIVE MAINTENANCE?

Total Productive Maintenance, or TPM,

is a lean maintenance strategy that
aims for zero breakdowns, zero
defects and zero work accidents.
The primary goals of TPM are to
eliminate waste caused by accidents,
emergency and unscheduled
downtime, defects and speed losses.
The Eight Pillars of TPM
What is Lean / 5S?
5S is a lean manufacturing
methodology used to help
eliminate waste, optimize
productivity and increase
efficiency.
It may also be referred to as
“5S Plus” or “6S” to
emphasize a critical aspect
of any workplace — safety.
Takt time is the available production
time divided by customer demand.
 Throughput time means its total
time taken for movement of the raw
material and information for
producing one product.
Cycle time is the time between the
moment an operation starts and
ends.
Lead Time is the time it takes for one
unit to go through the entire
production cycle, from taking the
order to payment receipt.
Six Big Losses
TOTAL QUALITY MANAGEMENT
 What is tqm?
Total Quality Management (TQM) is an enhancement to the traditional way
of doing business. It is a proven technique to guarantee survival in world-
class competition. Only by changing the actions of management will the
culture and actions of an entire organization be transformed.

Analysing the three words, we have

Total—Made up of the whole.
Quality—Degree of excellence a product or service provides.
Management—Act, art, or manner of handling, controlling, directing, etc.
Thus, TQM is the art of managing the whole to achieve excellence.

Two fundamental operational goals

Careful design of the product or service
Ensuring that the organization’s systems can consistently produce the design
 Six Basic Concepts of TQM

A committed and involved management to provide long-term

top-to-bottom organizational support.
An unwavering focus on the customer, both internally and
externally.
Effective involvement and utilization of the entire work force.
Continuous improvement of the business and production
process.
Treating suppliers as partners.
Establish performance measures for the processes.
By this we achieve excellence.
Quality Gurus &their major contribution
Evolution of tqm
Total Quality Management Principles
7 Quality Tools
 SMED
Single-minute exchange of die is the process of trying to make changeovers as fast as
possible. Quickly changing a process so that it can go from making one product to
making another helps reduce lead times and inventories and facilitate one -piece flow
production. It was first introduced by Shigeo Shingo.

Implementing Single Minute Exchange of Die (SMED):

Separate internal from external setup operations

Convert internal to external setup
Standardize function, not shape
Use functional clamps or eliminate fasteners altogether
Use intermediate jigs
Adopt parallel operations
Eliminate adjustments
Mechanization