World Class Manufacturing

Members:

Abinash Sahoo - 01(A)

Alkesh Dinakar - 03(A)

Kapil Agarwal - 12(A)

Mohan Kumar - 16(A)

Introduction• World Class Manufacturers are those

that demonstrate industry best practice. To achieve this companies should attempt to be best in the field at each of the competitive priorities (quality, price, delivery speed, delivery reliability, flexibility and innovation)..

• Organisations should therefore aim to maximise performance in these areas in order to maximise competitiveness. However, as resources are unlikely to allow improvement in all areas, organisations should concentrate on maintaining performance in 'qualifying' factors and improving 'competitive edge' factors. The priorities will change over time and must therefore be reviewed.

Tools for Achieving World Class

Manufacturing • Cost Control• Quality• External Flexibility• Internal Flexibility• Capacity to Change(Human Resource

management)• Innovation Capacity

Implementing World Class Manufacturing: Tools to

Measure and Record ProgressCritical Success Factor

World Class Manufacturing Tool

Measurement Indicators

1.Cost control

Just-in-time logistics, quality at source and supply chain management tools

･ Inventory holdings ･ Absence of defects and rework･ Cost of incoming materials

2. Quality Statistical Process Control, fool-proofing to prevent errors, Pareto analysis of types and causes of production defects

･ Customer return rates ･ Internal reject, rework and scrap rates･ Supplier quality performance

3. External flexibility

Just-in-time logistics, quality at source and supply chain management tools

･ Time from customer order to delivery ･ Delivery frequency and reliability to customers ･ Delivery frequency and reliability of suppliers

4. Internal flexibility

Cellular layouts, single unit flow, production pulling, kanban signalling system, single-minute exchange of dies for rapid machine

･ Machine changeover times･ Batch and lot sizes･ Inventory levels.In time

5. Capacity to change (Human resource development)

Multi-tasking, multi- skilling, quality circles, kaizen groups, training, incentive schemes.

･ Numeracy and literacy levels ･ Labour/management turnover levels ･ Absenteeism rates ･ Training expenditure and types of training ･ Employee development ･ Suggestion schemes/continu

ous improvement

6. Innovation capacity

Concurrent engineering, new product development techniques

･ R&D expenditure

･ Proportion of sales

from new products

For Achieving WCM

KAIZEN TOOLS PQCDSSIX SIGMA

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