World Class Manufacturing WCM is a process which

World Class Manufacturing (WCM) is a process which integrates the standalone processes of JIT, TPM, TQM, Lean Manufacturing, Six Sigma and Kaizen to offer an integrated and holistic solution which results in sustaining gains arising out of the improvement initiatives. The beauty of WCM is that it’s not only applicable to the operative level but also transcends into various desk based transactional processes. Further, the above enables an organization to build capability so as to harness / sharpen / create sources of competitive advantage for execution of the business strategy and achieving outstanding performance. We have developed a comprehensive implementation methodology for rolling out the above. It is designed to clearly demonstrate the simple ideas that breathe new life into any company industry. It offers a new way of thinking of being and of doing a great transformation in the individual and in the organization to gain sustaining benefits and growth. Copyright © 2013. All Rights Reserved with Purple.

World Class Manufacturing What is World Class Manufacturing ? World Class Manufacturing depends on martialing resources for continual rapid improvement. This involves recasting relationship among Suppliers, Purchasers, Producers and Customers. - Prof. Richard Schonberger - 1986 Copyright © 2013. All Rights Reserved with Purple.

World Class Manufacturing Excellence Initiatives Over Last 90 years 1922 1927 1938 1941 Industrial Growth with Mechanization, Productivity Increases Substantially Factories Redesigned for better use of Electric Motors 1982 US Industrial Production Develops 1981 Computer Assisted Design Six Sigma – Motorola 1983 / 84 1986 Statistical Process Control for Quality Lean Manufacturing 1979 1971 / 72 Robotics and Numerical Control 1989 / 90 Benchmarking ISO Standard Focused Factory 1992 Process Re. Engineering and Outsourcing 1994 Supply Chain Management 1947 World War II Search for Low Cost Manufacturing Areas 1951 R&D Departments Widespread Exploiting Wartime Innovations 1959 1955 Project Evaluation and Review Technique SQC for Acceptable Defect Level 1961 / 62 Critical Path Method (CPM) 1949 1995 1996 Six Sigma Central in Strategy World Class Manufacturing 1954

World Class Manufacturing How each of these initiatives deferred? q IE : Zero Waste q TQM : Zero Defect q TPM : Zero Default q JIT : Zero Stock q TEI : Zero Injury WCM : Integrates IE, TQM, TPM, JIT, TEI, Six Sigma, Lean & Kaizen Copyright © 2013. All Rights Reserved with Purple.

World Class Manufacturing What is Unique? q Flexible Logistics q Rapid Changeover and Machine Flexibility q Focus on quick New Product Development q Inspection Eliminated q Empowered Workers – Problem Solving, Widespread Idea Contribution Copyright © 2013. All Rights Reserved with Purple.

World Class Manufacturing What will your company achieve by adopting WCM? q Customer Satisfaction q Assured Quality q Quick and On Time Deliveries q Maximize Inventory Turns q Highly Engaged Workforce q Least Cost Manufacturing Copyright © 2013. All Rights Reserved with Purple.

World Class Manufacturing How will we make it happen? Step 1 : Through Diagnostic Step 2 : Identification of Priorities – Creating a Work Plan Step 3 : Widespread Workforce Involvement Step 4 : Structured Problem Solving Step 5 : Weekly, Monthly, Quarterly Reviews segmented on Lead Time Articulation Copyright © 2013. All Rights Reserved with Purple.