World Class Manufacturing

World Class Manufacturing World Class Manufacturing is essential way of running any Business for competitive advantage & long-term sustainability in today"s cut throat intensifying Market.

World Class Manufacturing is not methodology but Culture & Mindset of company.

?Unfortunately most of the companies are not really serious to implement it in real sense in companies due to lack of Leader’s Vison, Commitment, Will to create platform to implement the World Class Manufacturing although many companies talk about it & few companies try to implement World class Manufacturing in superficial way so it do not become deep rooted & fail to change company culture .

?5 S , Kaizen, Lean and Six Sigma, TPM, TQM & Lean Manufacturing etc are business improvement?methodologies and all?owe their origins to World class Manufacturing & improvement initiatives in the?Japanese and?American Manufacturing industries

?All improvement initiatives can be of great value to a business and its management team & applicable for all dept”s of Org , and is an integral part of selecting the best methodology to implement in any given situation.

?It is well said that improvement start from the Security Gate to all Dept of company World class Manufacturing is Culture & Mind set of Org.

1.??5 S … 5S is a systematic form of visual management utilizing everything from floor tape to operations manuals. It is not just about cleanliness or organization; it is also about maximizing efficiency and profit.?5S is a framework ?that emphasizes the use of a specific mindset and tools to create efficiency and value. It involves observing, analysing, collaborating, and searching for waste and also involves the practice of removing waste.

The 5S methodology is a systematic approach to workplace organization. This method includes the five steps of Sort, Set in Order, Shine, Standardize, and Sustain. Generally speaking, the steps of 5S involve going through items in a workspace, removing what's unnecessary, organizing items, cleaning, performing maintenance, and making sure these things become habits.

?2.???Kaizen …. Kaizen is a Japanese word meaning 'change for the better'?and is also known as 'continuous?improvement'.?It is a mindset or philosophy rather than being a tool to use.???

One of the most prominent?Japanese words associated with Kaizen is 'Muda'. 'Muda' means waste, and the Kaizen philosophy aims at cutting business waste through improving quality, increasing efficiency, reducing overproduction and unnecessary activities.

?Kaizen is?an approach to creating continuous improvement based on the idea that small, ongoing positive changes can reap significant improvements. Typically, it is based on cooperation and commitment and stands in contrast to approaches that use radical or top-down changes to achieve transformation. Ill result in saving both money and time.?

?Kaizen's core philosophy will facilitate innovation and improvement.?In short, this?continuous improvement strategy?can be a very powerful support for any improvement project, for as long as?the majority of?employees are on board.??

?3.????Lean Manufacturing … Lean?is focused on the removal of wastes and it defines waste as anything that fails to add value to the customer. Its focus on cutting business waste is the Lean methodology's main driver of continuous improvement. Lean particularly revolves around the 7 wastes that are killing business efficiency,

1. Transport?
2. Inventory?
3. Motion?
4. Waiting?
5. Overproduction?
6. Over Processing?
7. Defects?

Lean owes?it's?origins to the ingenuity of the?Ford?Motor?Company more than 100 years ago and has continued to evolve over time as business improvement concepts have also improved over time. Rather than overcomplicating things, this continuous improvement methodology aims at completing three main steps:??

1. Identification of wasteful activities?
2. Identification of the ways these wastes are killing business efficiency?
3. Elimination or reduction of these wasteful activities

?4.????TPM … Total productive maintenance is a complete system for maintenance of equipment that aims at achieving an optimal production environment devoid of defects, downtime, stoppages and accidents.

One distinct advantage of total productive maintenance is that it empowers the shop floor to work in a concerted manner to ensure that machines are functioning at their optimal performance.

8 Pillars of Total Productive Maintenance?

• Focused Improvement.
• Autonomy.
• Quality Maintenance.
• Planned Maintenance.
• Early Equipment Maintenance.
• Training and Education.
• Safety, Health and Environment.
• Office TPM

5.???Six Sigma …. While Kaizen and Lean both look at resources and ways to optimize a process, the core goal of Six Sigma is achieving consistent and reliable results. It is primarily focused on improving the quality of the result or outcome of the process. This is why it is sometimes referred to as a quality assurance methodology, despite the fact that it has been successfully applied beyond just quality improvements.

?As far as results go, Six Sigma strives for near perfection, where the process succeeds 99.99966% of the time. To achieve this seemingly impossible result, training and coaching are required in order to learn the tools and framework, modelled after the martial arts belt system. These results lead to lower costs, improved customer satisfaction, and helps drive continuous improvement in order to??to achieve higher and higher sigma levels.?

?6.????TQM… Total quality management (TQM) is the continual process of detecting and reducing or eliminating errors in manufacturing, streamlining?supply chain management , improving the customer experience, and ensuring that employees are up to speed with training. Total?quality management ?aims to hold all parties involved in the production process accountable for the overall quality of the final product or service.

?Which Process Improvement Methodology Is Best?For?Your Business?

5 S is all about making shop floor offices in order in terms of cleanliness , arrangement etc so it is first & must step for World Class Manufacturing implementation ..

Kaizen?tries to improve the business?as a whole by?creating a standard way of working, increasing efficiency and eliminating business waste.??

Lean?is all about eliminating waste to increase process speed and quality through the reduction of process?waste.??

TPM?is Total productive maintenance is a complete system for maintenance of equipment that aims at achieving an optimal production environment devoid of defects, downtime, stoppages and accident .

Six Sigma?is more focused on quality output (the final product). This is facilitated by finding and eliminating the causes of defects.??

TQM ?is defined as a continuous effort by the management as well as employees?of a particular organization to ensure long term customer loyalty and customer satisfaction. Remember, one happy and satisfied customer brings ten new customers along with him whereas one disappointed individual will spread bad word of mouth and spoil several of your existing as well as potential customers.

All above initiatives play role in developing an effective continuous improvement model and all can be used in conjunction with one another?depending on the specific problem you need to solve.?

Elimination of ‘wastes’ in order to improve process speed and quality through reduction of process wastes

The most important fact, however, is that one is not better than the other - you need, can benefit from the use of, and should be using all. The bottom-line is don’t waste lots of time and money trying to put ways of thinking and improving in place as these concepts/ tools are designed to save time and money. The ultimate goal will be Operational Excellence for Business Excellence and the spirit should be to improve, to change the paradigms, to change the culture, to change the current set of habits.??