World Class Manufacturing Is…

 A position of international manufacturing excellence, achieved by

developing a culture based on factors such as continuous
improvement, problem prevention, zero defect tolerance, customer-
driven just-in-time production, and total quality management
 The capability of a manufacturer to compete with any other
manufacturing organization in a chosen market, with the aspiration
of achieving world-beating standards in all organizational aspects.
World class manufacturing encompasses the practices of total
quality management, continuous improvement, international
benchmarking, and flexible working.

Definition sourced from Bnet Business Director

• World Class Manufacturing is a different set of concepts, principles,
policies and technique s for managing and operating a manufacturing
company.

• It is driven by the results achieved by the Japanese manufacturing

resurgence following World War II, and adapts many of the ideas
used by the Japanese to gain a competitive edge.

• It primarily focuses on continual improvement in :-

• Quality
• Cost
• Lead Time
• Flexibility
• Customer Service
• Innovation
 Lead Time Reduction
 Speed time-to-market
 Cut Operations cost
 Exceed customer expectations
 Manage the global enterprise
 Streamline outsourcing processes
 Improve business performance visibility
Implementations usually involve the following
philosophies and techniques:
 Make-to-order
 Streamlined flow
 Small lot sizes
 Families of parts
 Doing it right the first
time
 Cellular manufacturing
 Total preventive
maintenance
 Quick changeover
 Zero Defects
 Just-in-time
 Variability reduction
 High employee
involvement
 Cross functional teams
 Multi-skilled employees
 Visual signaling
 Statistical process
control
It is a means to achieve :
 High quality
 Low costs
 Delivery on time
 Increasing market share
 Higher profitability
 Achieving customer delight
 Long term viability
A successful continual improvements activities
consist of the following tasks:
 Clearmission, vision, values and objectives at the
management level and disseminated throughout
the organisation.
 Effective communication
 Well
planned and organized system
implementations.
 Equal opportunities for all the employees.
 Vertical
progression Vs horizontal moves
perception.
 Teamwork & empowerment of the shop floor
workers.
Policies world class companies pursue to achieve the
necessary contribution from employees :
 Learningprocess and the content of training; through
experience and self discovery.
 Mentoring and coaching; Train the trainers e.g. Managers
 Training and development as an investment.
 Inculcate a lifelong learning culture.
 Team building and team training activities with the
participation from senior and top management.
 Participation
at all level in the relevant training and
development.
 Anintegrated approach for training and development
plans that give training needs for the individual from
appraisal, but that clearly link to the organisation’s
mission, vision, values and objectives.
 12,000 companies were surveyed according to the
Malcolm Baldridge National Quality Award criteria. Out
of 1,039 in total, the breakdown were as follows:

Country World Class Recognition

Japanese 675
North American 221
West German 71
British 40
French. 32

The Malcolm Baldrige National Quality Award was created by Public Law 100-107,
signed into law on August 20, 1987. The Award Program, responsive to the purposes of
Public Law 100-107, led to the creation of a new public-private partnership. Principal
support for the program comes from the Foundation for the Malcolm Baldrige National
Quality Award, established in 1988.
 ‘Think Quality.’ Strive constantly to improve your product;
Inspired to seek ways to do everything better at all level; and cut
the product rejection rate.
 ‘Be Competitive.’ Match or exceed every improvement made by
the competitors; Competitive pricing; Ready and prepared to give
100 per cent service; Think creative to promote your products
with the objective to outperform competitors.
 ‘Treasure your employees.’ Treat workers fairly; Give all
employees equal consideration; Provide lifetime employment, or
at least, fire no one before exhausting every other possibility;
Share in the company’s good times with regular bonuses. In other
word, treat all employees like the conscientious, loyal, intelligent,
and hardworking people you want them to be. And tha’s what
they will surely be.