NITIN DATTA PAWAR

DPGD/JA12/0863
SPECIALIZATION :- OPERATIONS

WELINGKAR
institute of management development & research
Year September 2013
 DEFINATION:- World class 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, electronic and steel industry.
 World class manufacturing is a process driven approach where various
techniques and philosophy are used in one combination or other.
Some of the techniques are as follows:

Make to order
Streamlined Flow
Smaller lot sizes
Collection of parts
Doing it right first time
Cellular or group manufacturing
Total preventive maintenance
Quick replacement
Zero Defects
Just in Time
Increase
Flexibility & control to
satisfy customer on time,
every time

Managing through people,

teams and aligning all to
goals

Reduction of waste in the

manufacturing system

Product quality right first

time, every time
 S: Safety : To eliminate accident
Q: Quality : That satisfy customer expectation and requirement
C: Cost : To optimise production cost
D: Delivery : Reduce delivery time
E: Environment : Reduce environmental accidents to zero and reduce
negative environmental effects
Being the best

Delight the
customer

Being the lowest

cost producer
 World class manufacturing is a process driven
approach where various techniques and philosophy
are used in one combination or other.
Some of the techniques are as follows:
Make to order
Streamlined Flow
Smaller lot sizes
Collection of parts
Doing it right first time
 Cellular or group manufacturing
Total preventive maintenance
Quick replacement
Zero Defects
Just in Time
Increase consistency
Higher employee involvement
Cross Functional Teams
Multi-Skilled employees
Visual Signalling
Statistical process control
 What is the Problem?
Where?
What is the priority?
Evaluation of Results
Waste/ Loss
Analysis

Improvement
Right
and Expansion
methods

Implementation Benefit / Cost

Implementation with Discipline

Participation of all employees

 There are three main principles, which drive
world-class manufacturing.
Implementation of just in time and lean
management leads to reduction in wastage thereby
reduction in cost.
Implementation of total quality management
leads to reduction of defects and encourages zero
tolerance towards defects.
Implementation of total preventive maintenance
leads to any stoppage of production through
mechanical failure.
 Quality
Cost effective
Flexibility
Innovation
SAFETY
Workplace
Maintena
Quality organizatio Logistics
nce
COST n
DEPLOYMENT

Method & Total Total Total

Just in
Standards Quality Industrial Productiv
time
Control Eng. e main.
(JIN)
(TQC) (TIE) (TPM)
Quality Productiv Technical Service
Focus Improving ity Efficiency Level

Target
0 Defect 0 Waste 0 Breakdown 0 Stock

0 Accident
 The main aspects of the world-class manufacturing
are as follows:

Industrial culture area

Market/client area
Product development area
Operations area
E-Performance area
 Fiat Group
Chrysler
Royal Mail
Volvo
Ariston Thermo Group
Mahindra & Mahindra
Bombay Dyeing
Reynolds India
Hindustan Paper Corporation Ltd
Haldia Petrochemicals
Emani Group
Mittal Dhatu RashayanUdo
TOFA WCM Road Map

TOFA, which has been selected as the first Silver Factory of FIAT Group in 2009
with a 62-point WCM audit score, is trying to be the first Golden Factory
surpassing the 70-point in this year.
THANK YOU