Difference between revisions of "World class manufacturing"

m
m
Line 11: Line 11:
 
<li>[[Toyota production system]]</li>
 
<li>[[Toyota production system]]</li>
 
<li>[[Total Quality Control]]</li>
 
<li>[[Total Quality Control]]</li>
 +
<li>[[Group technology]]</li>
 
</ul>
 
</ul>
 
}}
 
}}
  
'''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:
+
'''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:
* [[Total Quality Control]] (TQC) which concerns company-wide [[quality]] control, the main emphasis is on people, and then the methods and equipment,
+
* Making the losses visible - it helps convince that changes are necessary
* [[Total productive maintenance]] (TPM)) which concerns the improvement of machinery and equipment and maximization of their productivity,
+
* Improving as a team - [[teamwork]] is required to solve sophisticated problems of production performance
* Total industrial engineering (TIE) which concerns the development of company-wide [[industry]],
+
* Process orientation - production is a [[value stream mapping|stream of value]]
* [[Just in time]] (JIT) means that the exact number of components needed for production is delivered to the next step in the right time.
+
* Standardization - if the solution is good, it should become a standard
  
==Principles of WCM==
+
==Evolution of the 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 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 main objectives of [[WCM]] methods are:
+
==The pillars of World Class Manufacturing==
# Maximizing the results of the production system, while respecting the software [[logistics]] and [[quality]] goals
+
The 10 '''technical''' pillars of World Class Manufacturing are:
# Ensure that the evolution of the production system, which is also aimed at strengthening the [[competitiveness]], including:
+
# Safety
#* Zero accidents
+
# Cost Deployment
#* Zero defects
+
# Focused improvement
#* Zero accidents or zero losses in all its processes
+
# Autonomous maintenance and workplace organization
# Increase of the [[knowledge]] and competence of personnel, as well as skills in solving problems with use of methods and tools of [[WCM]]
+
# [[Total productive maintenance|Professional maintenance]]
 +
# [[Quality control]]
 +
# Logistics & Customer service
 +
# Early equipment management
 +
# People development
 +
# Environment
  
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.  
+
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
 +
# Time and Budget
 +
# Level of Detail
 +
# Level of Expansion
 +
# 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.
  
'''See also:'''
+
==How to implement WCM?==
* [[Group technology|Group technology in manufacturing]]
+
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==
Line 40: Line 64:
 
* 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
 +
* [http://www.gobiztech.com/docs/Infor-Seven-Keys-World-Class-Manufacturing.pdf 7 keys to WCM]
 +
* [http://www.wcm-wcp.com World Class Manufacturing] by Richard J. Schonberger
  
 
{{a|Teresa Śpiewla}}
 
{{a|Teresa Śpiewla}}

Revision as of 10:16, 29 March 2016

World class manufacturing
Primary topic
Related topics
Methods and techniques

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:

  • Making the losses visible - it helps convince that changes are necessary
  • Improving as a team - teamwork is required to solve sophisticated problems of production performance
  • Process orientation - production is a stream of value
  • Standardization - if the solution is good, it should become a standard

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.

The pillars of World Class Manufacturing

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?

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

Author: Teresa Śpiewla