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Unit 5: World Class Manufacturing

World class manufacturing is a set of concepts and principles for efficiently operating and managing a manufacturing company based on techniques pioneered by Japanese manufacturers after WWII. It focuses on just-in-time production, continuous process improvement, reducing waste and defects, and meeting customer needs. Key aspects include cellular manufacturing, reducing setup times, work-in-progress and postponement of changes until final production. The goals are to maximize efficiency, effectiveness and profits while benefiting society.

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Kunal Gupta
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120 views13 pages

Unit 5: World Class Manufacturing

World class manufacturing is a set of concepts and principles for efficiently operating and managing a manufacturing company based on techniques pioneered by Japanese manufacturers after WWII. It focuses on just-in-time production, continuous process improvement, reducing waste and defects, and meeting customer needs. Key aspects include cellular manufacturing, reducing setup times, work-in-progress and postponement of changes until final production. The goals are to maximize efficiency, effectiveness and profits while benefiting society.

Uploaded by

Kunal Gupta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Unit 5

World class
manufacturing
Meaning:
• World Class Manufacturing is a set of
concepts, policies, techniques, and principles
for operating and managing
a manufacturing company. The concept
ofWorld Class Manufacturing is based on the
positive results achieved by
Japanese manufacturingcompanies
after World War II.
• 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 • Just in Time


• Streamlined Flow • Increased consistency
• Smaller lot sizes • Higher employee
• Collection of parts involvement
• Doing it right first time • Cross Functional Teams
• Cellular or group • Multi-Skilled employees
manufacturing • Visual Signaling
• Total preventive • Statistical process control
maintenance
• Quick replacement
• Zero Defects
 steps for efficiency:
• Reduction of set up time and in tuning of machinery: It is
important that organizations are able to cut back time in
setting up machinery and also tune machinery before
production.
• Cellular Manufacturing: It is steps
important that production
processes are divided into according to its nature, with similar
nature combined together.
• Reduce WIP material: It is normal tendency of manufacturing
organization to maintain high levels of WIP material.
Increased WIP leads to more cost and decreased WIP induces
more focus on production and fast movement of goods.
• Postpone product mutation: For to achieve a
higher degree of customization many changes are
made to final product. However, it is important
that mutation conceived for the design stage
implement only after final operation.
• Removal the trivial many and focus on vital few: It
is important for organization to focus on
production of products which are lined with
forecast demand as to match customer expectation
Principles of 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.
Features:
• According to the policies set
• Efficient
• Effective
• Acc. To customer needs
• Profitable
• Socially good
• Zero defects
• Optimal use of resources
Importance:
• Helps in creating efficiency
• Creating effectiveness
• Helps in achieving goals
• Earning profit
• Society welfare
• Upgradin goods
• Standardising goods
Lean manufacturing:
• Lean manufacturing is a systematic method
for waste minimization within a manufacturing
system without sacrificing productivity, which
can cause problems. Lean also takes into
account waste created through overburden
and waste created through unevenness in
work loads.
Five principles of lean manufacturing

• 1. Identify value from the customer's


perspective
• 2. Map the value stream.
• 3. Create flow.
• 4. Establish a pull system
• 5. Pursue perfection with continual process
improvement, or kaizen
Technological hardware used in lean manf.:

• Robots:refers to a piece o automated


equipment,typically pogrammable,that can be
used for moving material to be worked on or
for assembling components into a larger
device.
• Numerically controlled:tool that can be run by
a computer programme that directs the
machine in its operations.
Contd.
• Computer numerically controlled:programs can
be developed and stored locally.it saves real
time,on line programme development
capabilities so that operators can implement
engineering changes rapidly.
• Distributed numerically controlled:consists of
numerous CNC tools linked together by a
larger computer system that downloads NC
programs to the distributed machine tools.

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