7 steps to World Class Manufacturing

Competitive Edge
FICCI Management Consultants
World-Class Manufacturing

World class manufacturing means being

successful in your chosen market against
any competition—regardless of size, country
or resources.
World-Class Manufacturing

It means matching or exceeding

any competitor on:
• Quality
• Innovation
• Design
• Flexibility
• Cost &
• Customer service.
World-Class Manufacturing

It means that you are in control and your

competitors struggle to emulate your
success.
 World-Class
Manufacturing

Being in control also means that you are

prepared and will not be thrown by
unexpected changes in demand,
technology, circumstances or competition.
7 steps to world Class manufacturing

1. Focus on ‘Competitive Quality’

2. Implement Lean manufacturing
3. Achieve cost efficiency
4. Reduce Time-to-Market
5. Exceed Customer Expectations
6. Streamline Outsourcing Processes
7. Have a global perspective
 1. Focus on ‘Competitive
Quality’

Design Excellence
Assessment of performance
Continuous improvement guidelines
Model of Continuous improvement
SMAIC in action
Measures of Mfg. excellence
Benchmarking - technique
Manufacturing best practices
TQM Rolling plan
Benchmarking with Japan
BPR
Kaizen
PDCA
Reliability improvement
FMEA
Six sigma
 2. Implement Lean
Manufacturing systems
Lean Management
Non-Value Adding Activities
Reducing set-up time
Five S-technique
Just In time
Total Productivity Maintenance
TPM Checklist
Supplier quality improvement
Supplier evaluation
Supplier best practices
Supply chain
Takt Time
Taguchi Methods
Root cause analysis
Kanban
 3. Achieve cost efficiency

Quality,Cost & Profit

Cost of Quality
Quality Cost-Function Wise
Non-Value Adding Activities
Gemba Kaizen - A low cost approach
Analysis of variance
Controlling variation
Mistake Proofing
Pokayoke
Reducing Defectives through FMEA
Waste Assessment
Waste Reduction
Design of experiments
 4. Reduce Time-to-Market

Time based competition

Creativity & innovation

Niche Marketing

SCAMPER

New product development

Risk Analysis

Risk Management

Ten commandments of time

 5. Exceed Customer
Expectations
Are you a customer driven org.
Customer expectations
Exceeding expectations
Competitive Edge
Customer supplier model
Internal health
Quality
Quality MIS
Quality management principles
Customer satisfaction measurement
Customer loyalty
Customer practices of global leaders
Customer survey forms
Quality Function Deployment
 6. Streamline Outsourcing
Processes

Process classification framework

Principles of outsourcing

Outsourcing of manufacturing operations is a common practice

today because it offers flexibility. Outsourcing can often save lot of
time & money for an organization. It enables the organizations to
focus on their core competencies.
 7. Have a Global perspective

International Marketing
 Research, Artwork, Design and Development

Pravin Rajpal
Mr.Pravin Rajpal is a Quality Counsellor with FICCI Quality Forum. He is a Chartered
Accountant with more than 20 years of work experience in some of the best
professionally managed companies.

He is the pioneer of CD-ROM based quality management training in India and has
developed 7 CD ROMs on various topics of Quality Management.

More information
For any further clarification / information on the topics in this CD please contact him at
pravinrajpal@ficci.com.