World Class Manufacturing

Manufactura de Clase Mundial

TECHNICAL & MANAGERIAL
PILLARS
Professor: IE Johnnathan Fernando Gutiérrez Cruz
i i j f g c @ gmail.com
833 2800 500
Group IRREG 1
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WCM is a structured production system finalized to eliminate
all types of wastes and losses by applying standardized
methods for long lasting improvements.

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Each pillar is focused on a
specific aspect of the Plant, owns
defined targets and it is guided
with dedicated methods and a
common structure divided in 7
steps. Each step identifies a
phase and the area of application
of the methods.

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Technical
Pillars
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Safety (SAF)

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 STEP 7: Full implementation of a
preventive safety standard System
STEP 6: Autonomous safety
standards
STEP 5: Autonomous audit to verify
application of preventive countermeasures
STEP 4: Safety audit with training of
people
STEP 3: Definition of safety
standards
STEP 2: Implementation of
countermeasures also in similar areas
STEP 1: Analysis of accidents and
their root cause
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Cost Deployment (CD)

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 STEP 7: Implementation of improvement plan
trough F-Matrix (Pérdidas / Planes de Acción)
STEP 6: Evaluation of improvement costs for losses and
wastes reduction trough E-Matrix ("Pérdidas / Ganancias de
gestión potenciales")
STEP 5: Identification of saving methods from losses and
wastes trough D-Matrix (“Pérdidas / Métodos / Índice ICE”)
STEP 4: Calculation of losses and wastes
costs trough C-Matrix (“Costos/Pérdidas”)
STEP 3: Classification of losses and wastes trough
B-Matrix ("Pérdidas Causales/Resultantes")
STEP 2: Identification of losses and wastes
trough A-Matrix (“Pérdidas/Dónde”)
STEP 1: Quantify the total costs of
transformation process

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Focus Improvement (FI)

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 STEP 7: Expansion form target area to plant
of focus improvement methodology

STEP 6: Benefits/Costs analysis

STEP 5: Application of problem solving
method PDCA to open projects

STEP 4: Creation of a Project Team

STEP 3: Definition of the project for
focus improvement
STEP 2: Classification of losses and
wastes
STEP 1: Definition of a target area
for Focus Improvement
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Autonomous Maintenance (AM)

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 STEP 7: Total implementation of a
full AM plan
STEP 6: Standardization of AM
activities on the machine
STEP 5: Autonomous inspection

STEP 4: General inspection

STEP 3: Definition of a standard for
cleaning and lubrication
STEP 2: Removal of dirt causes and
of areas difficult to clean
STEP 1: Preliminary inspection and
general cleaning
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Workplace Organization (WO)

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 STEP 7: Implementation of Standard
working sequences
STEP 6: Improvement of WO
standards
STEP 5: Reduction of stocks areas
with application of Just in Time
STEP 4: Training on product characteristics and general
inspection on instruments and equipment of the workplace
STEP 3: Definition of preliminary
standards for WO
STEP 2: Process reorganization

STEP 1: Preliminary cleaning

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Professional Maintenance (PM)

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 STEP 7: Monitor maintenance costs
for an improved Maintenance system
STEP 6: Definition of a proactive
Maintenance system
STEP 5: Definition of a preventive
Maintenance system
STEP 4: Analysis of weak point to
increase lifetime of components
STEP 3: Definition of maintenance
standards
STEP 2: Breakdown analysis
STEP 1: Prevention of machine
degradation
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Quality Control (QC)

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 STEP 7: Improve methods for
maintaining conditions for zero defects
STEP 6: Maintain conditions for zero
defects
STEP 5: Define conditions for zero
defects
STEP 4: Reduce and remove all root
cause of potential chronic losses
STEP 3: Analyze chronic loss factors
STEP 2: Restorate base conditions
and improve operative standards
STEP 1: Analyze current conditions

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Logistic / Customer Service (LOG)

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 STEP 7: Standard sequence plan for
handling
STEP 6: Integration of Purchase,
Production and Shipping
STEP 5: Improvement of internal
and external logistics
STEP 4: Total matching of Production
plan with material delivery
STEP 3: Improvement of external
logistics
STEP 2: Improvement of internal
logistics
STEP 1: Definition of production areas
requirements for supplied materials
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Early Equipment Management / Early
Product Management ( EEM / EPM )

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 STEP 7: Ramp up
STEP 6: Control of functionalities
and analysis of risks
STEP 5: Installation of the machine
in the plant
STEP 4: Building of the machine/
Product prototype
STEP 3: Definition of a detailed
project
STEP 2: Preliminary setting of the
project
STEP 1: Strategic Plan

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People Development ( PD )

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 STEP 7: Technical and methodological
competencies at all levels
STEP 6: Diffusion of technical
competencies
STEP 5: Identification of a plan to
strengthen competencies
STEP 4: Creation of an advanced
training system
STEP 3: Realize projects to help team
members competencies development
STEP 2: Create a system to develop
competencies
STEP 1: Define principles and
priorities
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Environment (ENV)

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 STEP 7: Maintain an Environmental
friendly plant
STEP 6: Plan for environmental
impact reduction
STEP 5: Definition of a system for
environmental monitoring
STEP 4: Energy saving and control of
chemicals
STEP 3: Definition of temporary
standards
STEP 2: Prevention from
contaminations
STEP 1: Comprehension of
environment regulation
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LA ULTIMA DIAPOSITIVA ES DE TAREA PARA LA CLASE DEL JUEVES

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