Difference between revisions of "World class manufacturing"

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'''World Class Manufacturing''' is a method of improving the cycle of production [[logistics]]. The main objective of the method is to increase [[quality]] and reduce production costs. The method is based on the concepts of:
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{{infobox4
* [[Total Quality Control]] (TQC) which concerns company-wide [[quality]] control, the main emphasis is on people, and then the methods and equipment,
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|list1=
* [[Total productive maintenance]] (TPM)) which concerns the improvement of machinery and equipment and maximization of their productivity,
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<ul>
* Total industrial engineering (TIE) which concerns the development of company-wide [[industry]],
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<li>[[Kaizen]]</li>
* [[Just in time]] (JIT) means that the exact number of components needed for production is delivered to the next step in the right time.
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<li>[[Quality management]]</li>
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<li>[[Konnyaku stone]]</li>
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<li>[[Quality management system]]</li>
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<li>[[Armand Feigenbaum]]</li>
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<li>[[Lean manufacturing]]</li>
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<li>[[Toyota production system]]</li>
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<li>[[Process improvement]]</li>
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<li>[[Lean supply chain management]]</li>
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</ul>
 +
}}
  
==Principles of WCM==
 
The basic assumptions of the method [[WCM]] is zero waste, zero defects, zero breakdowns and zero storage. These assumptions are intended to improve productivity, improve [[quality]], technical ability and level of [[service]].
 
  
The main objectives of [[WCM]] methods are:
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'''World Class Manufacturing''' (WCM) is a [[method]] of improving the cycle of [[production]] and [[logistics]]. The main objective of the method is to increase [[quality]] and reduce production costs. The main rules of the WCM are:
# Maximizing the results of the production system, while respecting the software [[logistics]] and [[quality]] goals
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* Zero waste
# Ensure that the evolution of the production system, which is also aimed at strengthening the [[competitiveness]], including:
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* [[Zero defects]]
#* Zero accidents
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* Zero breakdowns
#* Zero defects
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* Zero inventory
#* Zero accidents or zero losses in all its processes
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The idea of zero comes from the numerous discussions about what the [[level of quality]] should be. Apart from setting realistic objectives, the WCM simplifies things and sets the ideal, to which all enterprises should endeavour.
# Increase of the [[knowledge]] and competence of personnel, as well as skills in solving problems with use of methods and tools of [[WCM]]
 
  
These goals of [[WCM]] method require a large commitment from managers, but also from each employee. Objectives are achieved through implementation of appropriate methodologies, a set of methods and tools, and change in the behavior of people.  
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==Evolution of the WCM==
 +
The World Class Manufacturing is a concept developed by FIAT and partnering companies in 2005. However the name was used earlier by Richard J. Schonberger in 1986. Both ideas are different and not linked.  
  
'''See also:'''
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The original Schonberger's idea was based on the role of staff, economy, responsibility centers, zero defects, [[product]] and [[process]] design, partnership, simplicity.
* [[Group technology|Group technology in manufacturing]]
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 +
The WCM can be viewed as yet another set of known quality methods, but ordered differently, with different importance. It stands as a competitive idea to [[Toyota production system]], [[Lean management]] or [[Six sigma]]. The similarities between those ideas are visible, especially on operation level.
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 +
 
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==The pillars of World Class Manufacturing==
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The 10 '''technical''' pillars of World Class Manufacturing are:
 +
# Safety
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# [[Cost]] Deployment
 +
# Focused improvement
 +
# [[Autonomous maintenance]] and [[workplace]] [[organization]]
 +
# [[Total productive maintenance|Professional maintenance]]
 +
# [[Quality control]]
 +
# Logistics & [[Customer]] [[service]]
 +
# Early equipment [[management]]
 +
# People development
 +
# [[Environment]]
 +
 
 +
The 10 '''managerial''' pillars of World Class Manufacturing are:
 +
# Management Commitment
 +
# Clarity of Objectives
 +
# Route map to WCM
 +
# Allocation of Highly Qualified People to Model Areas
 +
# Commitment of the Organization
 +
# Competence of Organization towards Improvement
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# Time and Budget
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# Level of Detail
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# Level of Expansion
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# [[Motivation]] of Operators
 +
The managerial pillars create a foundation for technical ones. It is not possible to achieve WCM using only one of those sets of pillars.
 +
 
 +
==How to implement WCM?==
 +
There are several steps to implement WCM idea:
 +
# Reduce the lead times - the ability of sooner delivery can be decisive for success on the [[market]].
 +
# Reduce time-to-market - the markets [[demand]] quick response. The R&D and [[marketing]] processes should be optimised.
 +
# Cut operations costs - costs have to be cut wisely. Identify operations that don't create a value and remove them.
 +
# Exceed customer expectations - the customer expectations change so rapid, that the [[enterprise]] should exceed them, to keep up to speed with the market. The organization should know what customer will want even earlier than the customer thinks about it.
 +
# Manage the global enterprise - limiting the market to one country only is limiting the possibilities. Even small and medium enterprises can globalize their operation using [[internet]].
 +
# Streamline [[outsourcing]] processes - it is impossible to be the best in everything. The organization should increase its flexibility using extensive cooperation.
 +
# Improve business performance - the performance should be continuously improved using [[lean manufacturing]] or other concepts.
  
 
==References==
 
==References==
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* Brian H. Maskell (1991) ''[https://books.google.pl/books?id=H5qxOXYZ7d0C Performance Measurement for World Class Manufacturing]'', CRC Press
 
* Brian H. Maskell (1991) ''[https://books.google.pl/books?id=H5qxOXYZ7d0C Performance Measurement for World Class Manufacturing]'', CRC Press
 
* Ketter S. (2006) ''[http://www.fiatgroup.com/it-it/shai/iinfo/presentations/Documents/World%20Class%20Manufacturing%20-%20Towards%20excellence%20at%20Fiat%20Group.pdf World Class Manufacturing - towards excellence at Fiat Group]'' - presentation
 
* Ketter S. (2006) ''[http://www.fiatgroup.com/it-it/shai/iinfo/presentations/Documents/World%20Class%20Manufacturing%20-%20Towards%20excellence%20at%20Fiat%20Group.pdf World Class Manufacturing - towards excellence at Fiat Group]'' - presentation
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* [http://www.gobiztech.com/docs/Infor-Seven-Keys-World-Class-Manufacturing.pdf 7 keys to WCM]
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* [http://www.wcm-wcp.com World Class Manufacturing] by Richard J. Schonberger
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* [http://wenku.baidu.com/view/07c001d2240c844769eaeea2.html World Class Manufacturing] by Hajime Yamashina
  
{{a|Teresa Śpiewla}}
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{{aa|Slawomir Wawak}}
 
[[Category:Quality methods and techniques‎]]
 
[[Category:Quality methods and techniques‎]]
 
[[Category:Production management]]
 
[[Category:Production management]]
 
[[pl:Metoda WCM]]
 
[[pl:Metoda WCM]]

Latest revision as of 18:36, 19 August 2019

World class manufacturing
See also


World Class Manufacturing (WCM) is a method of improving the cycle of production and logistics. The main objective of the method is to increase quality and reduce production costs. The main rules of the WCM are:

The idea of zero comes from the numerous discussions about what the level of quality should be. Apart from setting realistic objectives, the WCM simplifies things and sets the ideal, to which all enterprises should endeavour.

Evolution of the WCM[edit]

The World Class Manufacturing is a concept developed by FIAT and partnering companies in 2005. However the name was used earlier by Richard J. Schonberger in 1986. Both ideas are different and not linked.

The original Schonberger's idea was based on the role of staff, economy, responsibility centers, zero defects, product and process design, partnership, simplicity.

The WCM can be viewed as yet another set of known quality methods, but ordered differently, with different importance. It stands as a competitive idea to Toyota production system, Lean management or Six sigma. The similarities between those ideas are visible, especially on operation level.


The pillars of World Class Manufacturing[edit]

The 10 technical pillars of World Class Manufacturing are:

  1. Safety
  2. Cost Deployment
  3. Focused improvement
  4. Autonomous maintenance and workplace organization
  5. Professional maintenance
  6. Quality control
  7. Logistics & Customer service
  8. Early equipment management
  9. People development
  10. Environment

The 10 managerial pillars of World Class Manufacturing are:

  1. Management Commitment
  2. Clarity of Objectives
  3. Route map to WCM
  4. Allocation of Highly Qualified People to Model Areas
  5. Commitment of the Organization
  6. Competence of Organization towards Improvement
  7. Time and Budget
  8. Level of Detail
  9. Level of Expansion
  10. Motivation of Operators

The managerial pillars create a foundation for technical ones. It is not possible to achieve WCM using only one of those sets of pillars.

How to implement WCM?[edit]

There are several steps to implement WCM idea:

  1. Reduce the lead times - the ability of sooner delivery can be decisive for success on the market.
  2. Reduce time-to-market - the markets demand quick response. The R&D and marketing processes should be optimised.
  3. Cut operations costs - costs have to be cut wisely. Identify operations that don't create a value and remove them.
  4. Exceed customer expectations - the customer expectations change so rapid, that the enterprise should exceed them, to keep up to speed with the market. The organization should know what customer will want even earlier than the customer thinks about it.
  5. Manage the global enterprise - limiting the market to one country only is limiting the possibilities. Even small and medium enterprises can globalize their operation using internet.
  6. Streamline outsourcing processes - it is impossible to be the best in everything. The organization should increase its flexibility using extensive cooperation.
  7. Improve business performance - the performance should be continuously improved using lean manufacturing or other concepts.

References[edit]

Author: Slawomir Wawak