Scribd Logo
Upload

Welcome to Scribd!

  • 129 views

    Name

    Uploaded by

    Hisham Elbdrawy
    This document provides an introduction to World Class Manufacturing (WCM). It defines WCM as a structured production system that involves the entire organization from top to shopfloor in continuously improving performance by eliminating waste and losses. It outlines the 10 managerial and 10 technical pillars of WCM and describes the pillar approach using a 7-step model area selection process to implement improvements. The goal of WCM is to achieve world-class levels of safety, quality, cost, delivery and morale.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Name

    Uploaded by

    Hisham Elbdrawy
    129 views14 pages
    This document provides an introduction to World Class Manufacturing (WCM). It defines WCM as a structured production system that involves the entire organization from top to shopfloor in continuously improving performance by eliminating waste and losses. It outlines the 10 managerial and 10 technical pillars of WCM and describes the pillar approach using a 7-step model area selection process to implement improvements. The goal of WCM is to achieve world-class levels of safety, quality, cost, delivery and morale.

    Original Description:

    bhbkjl

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides an introduction to World Class Manufacturing (WCM). It defines WCM as a structured production system that involves the entire organization from top to shopfloor in continuously improving performance by eliminating waste and losses. It outlines the 10 managerial and 10 technical pillars of WCM and describes the pillar approach using a 7-step model area selection process to implement improvements. The goal of WCM is to achieve world-class levels of safety, quality, cost, delivery and morale.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    129 views14 pages

    Name

    Uploaded by

    Hisham Elbdrawy
    This document provides an introduction to World Class Manufacturing (WCM). It defines WCM as a structured production system that involves the entire organization from top to shopfloor in continuously improving performance by eliminating waste and losses. It outlines the 10 managerial and 10 technical pillars of WCM and describes the pillar approach using a 7-step model area selection process to implement improvements. The goal of WCM is to achieve world-class levels of safety, quality, cost, delivery and morale.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 14

    WCM

    INTRODUCTION
    CHRIS BAKER
    GROUP MANUFACTURING EXCELLENCE CAPABILITIES
    MANAGER
    English, live in Manchester.
    Joined Unilever in 1997.
    2 Children.

    Operational Background from


    SUs.
    Electrical Engineer by training.

    Key Roles:-
    Project Manager
    Technical Manager
    Operations Manager
    Quality Improvement Project
    What is WORLD CLASS
    MANUFACTURING
    World ?
    Class Manufacturing
    (WCM) is a structured and
    integrated production system
    that involves all site’s processes
    and the entire organization from
    top to shopfloor people.

    WCM target is to
    continuously improve
    site’s performance
    eliminating waste &
    losses.
    Management Safety
    Commitment

    Clarity of Cost
    objectives Deployment

    Route map to Focus


    WCM Improvement
    WCM Pillars

    Allocation of
    highly Autonomous
    qualifed Activities
    people

    Commitment Professional
    of the Maintenance
    organization

    Competence
    of the Quality
    organization

    Logistics &
    Time &
    10 Technical Pillars

    Customer
    10 Managerial Pillar

    Budget Service

    Level of EEM & EPM


    details

    Level of People
    expansion Development

    Motivation of Environment
    operators
    WCM is not….
    ….WCM is
     WCM is NOT WCM is
    A project A program, a way of working

    A toolkit of methods and tools Integrated production system

    Restructuring program Continuous learning-improvement

    A technical job for operators and program

    engineers A leadership and management

    Top-down OR bottom up program

    An activity oriented program Top-down AND bottom-up approach

    Cost cutting program A results oriented program

    A safety-quality and productivity

    improvement program

    The Toyota style is not to create results by working hard.


    It is a system that says there is no limit to people’s
    creativity. People don’t go to Toyota to ‘work’ they go
    5
    there to ‘think’” - Taiichi Ohno
    WCM – Pillar approach

    7
    steps

    Pillar score

    0-5

    reactiv
    e proactiv
    preventi e
    ve
    WCM – Pillar Approach
    Model Area selection: most critical
    Model Area
    area, with highest losses for each specific Implementation
    pillar

    Safety = highest accidents/incidents


    7 Steps
    area Expansion
    AM = highest BDs losses due to lack of 1
    2
    basic conditions Application of pillar

    PM = highest BDs losses due to lack of 7 steps approach

    maintenance in Model Area to


    create knowledge
    Other Areas
    Extension
    Extension in other areas 3
    After reaching a certain step in the model
    area, same approach is applied in other areas.

    AM = after reaching step 3 in model area with


    proved results team expand AM in the second
    most critical area
    WCM Score: 0-100 points
    World
    Gold 85-
    Class
    70-84 100 pts
    Silver pts

    60-
    Bronze
    69 pts Be the WC leader
    50- in Q, C and D in

    Beginne business.

    59 pts Achieve a ca. 50% cost


    1-
    rs substantial gains
    in Q, C and D in
    reduction

    manufacturing
    49 Establish the basic
    competence.
    4-5
    pts
    conditions for
    25 – 40% cost
    competitive
    reduction
    manufacturing
    Years
    10 – 20% cost 3 years
    reduction

    2 years
    1 year
    WCM Ambition
     Growing skills and Capability – “Zero Gaps”

     Zero Accident & Zero First Aid

     Zero machine breakdown

     Zero quality defects

     Zero customer claims

     Zero minor stoppages

     Zero waste & losses


    WCM Audits Completed
    Last Score # Audits
    38
    37

    31 31

    25
    24

    20
    17
    14 14
    13 13
    11 11
    9 9 9
    8 8
    7 7
    6 6 6
    5 5
    4
    4 4 4 4 4
    3 3
    2
    1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
    Increasing the speed…
    … to meet business
    opportunities
    TECHNICAL SKILLS UPGRADE IS
    PIVOTAL TO ELIMINATE LOSSES AND
    WASTE IN OUR LINES
    Top Losses (WCM sites)

    You might also like