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CHAPTER-2

• WORLD CLASS MANUFACTURING




•      AN OVERVIEW
Towards 21st Century
 management of mfg. companies
• Mode                    • Assessment
• i-Management by Edict   Inconsistent,wasteful

• ii-Management by        Inconsistentquicker,wasteful
  procedure                  of talent

• iii-Management by       High level wisdom,limits
• Policies                  empowerment
• iv-Management by
  Principals              Customer focused,employee
                            driven,data based
Customer based principals
• 1-Team up with customers,organize by families of
  customers to products
• 2-Capture and apply customer,competitive and
  best practice information
• 3-Dedicate to continual,rapid improvement in
  quality,response time,flexibility and value
• 4-Frontline employees involved in change and
  strategic planning
• 5-Cut to few best components,operations and
  suppliers
GLOBAL MARKET
• Markets are becoming more global in nature
• Consumer demand is more homogenized on
  international basis
• An international business organization is a firm tht
  engages in cross-border transactions
• When operating in global market,a traditional
  company is at a “competitive
  disadvantage”because of inadequate
  products,wrong scale of operations,wrong way to
  produce and wrong way to market its products
GLOBAL MARKET(contd.)
• This has resulted in emergence of following
• 1-”Multinational corporation”-is a firm with
  extensive involvement in international business
• 2-”Global company”is a firm that integrates
  operations from different countries,considers
  world s single market
• 3-”Transnational company” is a firm that seeks to
  combine the benefits of global scale efficiencies
  with benefits of local responsiveness
GLOBAL MARKET (contd.)
• Demand for products is considered on a
  worldwide .This results into higher
  economies of scale and lower costs.
• Logistics and inventory control systems are
  global in nature
• Within the global arena ,competition has
  become intense due to greater number of
  players and existence of opportunities
GLOBAL MARKET(CONTD.)
• The world wide customers evaluate quality of
  productsservices from various dimensions such as
  performance,features,reliability,serviceability,dura
  bility,appearance ,customer service and safety
• This calls for improvement in productsservices to
  meet the expectations of customer
• Companies who have excelled on the international
  level are referred as “World class companies”
• “World class company “means that each product
  service would be considered “best in class” by its
  customers.
BECOMING WORLD CLASS
• World class performance comes from world class
  practice,which is created by world class
  management
• Quality is no longer viewed as an act of faith but
  as a contributor to business results
• In going beyond quality ,the focus should provide
  ,new challenges and new targets and reinforce
  what has already been achieved
BECOMING WORLD CLASS
          (CONTD.)
• QUALITY MATURITY PHASES-
• 1-Management decides they need quality
• 2-Management learnstalks about quality
• 3-Quality begins to be seen as a reality
• 4-Embedding the quality process
• 5-CEO establishes benchmarks from external
  sources and drives the organization
• 6-Quality process and business objectives get
  integrated
• 7-The company has become lean,fast and capable
  .means “World class”
GLOBALISATION OF
           PRODUCTION
•   Objectives
•   1-Reduce costs
•   2-Reduce risks
•   3-Improve supply chain
•   4-Provide better goods and services
•   5-Attract new markets
•   6-Learn to improve operations
•   7-Attract and retain global talent
WORLD CLASS
          MANUFCTURING
• Factors affecting global business conditions
• 1-Reality of global competition
• 2-Quality,customer & cost challenges
• 3-Rapid expansion of advanced manufacturing
  technology
• 4-Continued growth and importance of service
  sector
• 5-Scarcity of production resources
• 6-Social responsibility issues
Global competition reality
• India,s liberalized economic policy started in 1992
• Means Liberalization,Privatization & globalization
• Indian manufacturers face tough competition from
  foreign companies
• Also inflation,fluctuating currency,turbulent
  interest rates,volatility in international stock
  market,huge national debts of many
  countries,trade imbalance etc have created
  complex financial conditions in global businesses
• Global business in future will have the objective
  of “perfect product” & “service quality”
TQM IN WORLD CLASS
      MANUFCTURING
• Many smalllarge companies have adopted total
  quality management as a way of life
• They focus on customers needs , and structure
  their organization to deliver to these needs
• Organization culture gets changed to achieve
  perfect quality
• To respond to customer,s needs ,many firms hve
  adopted TQM,ISO 9000 and JIT manufacturing to
  ensure reduced inventory costs and flexible
  operations
AUTOMATION IN
     PRODUCTIONSERVICE
         OPERATIONS
• i-Computer aided design(CAD)-Specialized
  softwarehardware for design of products
• ii-Computer aided manufacturing(CAM)-
  Translation of CAD information in automated
  production machinery
• iii-Flexible manufacturing systems(FMS)
• Computers give instructions,robots handle parts
  and materialsmachines setting are changed
  automatically to produce different products
Automation in productionservice
      operations(contd.)
• iv-Automated storage and retrieval
  systems(ASRS)-Computer controlled
  warehouses.Includes automatic placement
  removal of parts as also automatic transportation
  of parts
• v-Automatic identification system(AIS)-Bar
  coding,radio frequencyoptical characters are
  designed to present data and are read by scanners
  that transmit data to computers
ISSUES
• 1-Growth of service sector-Service and
  manufacturing sectors are inter-related
• 2-Scarcity of production resources-Scarcity of
  various raw materials,personal skills require
  judicious allocation of resources
• 3-Social impacts
• i-Environmental impact-needs concern about
  about waste disposal,airwaterground pollution
  etc
• ii-Employee impact-Labor shortages,statefederal
  laws etc require development of fair treatment
GLOBAL COMPETITIVENESS
• “Competitiveness” can be defined as the long term
  viability of firm and is also measured by its
  “market share” or its “profitability”
• “Competitiveness” of a nation in the sense of its
  aggregate competitive success in all markets
• DistinctiveCore competencies represent
  competitive advantage in capturing markets
• Examples of DistinctiveCore competency are
  automated production
  technology,skilleddedicated work force,ability to
  bring new products in production,talented work
  force etc
Competitive priorities of
          Manufacturing
• 1-line production costs-Redesign of products,new
  production technology,increased rate of
  production,Reduction of scrap,reduction of
  inventories
• 2-Delivering performance-higher finished goods
  inventory,Faster production rates,Quicker
  shipping methods,realistic promises,Better control
  of production orders,Better information system
Competitive priorities of
       manufacturing(contd.)
• 3-High quality productServices-improve
  productservices appearancemalfunction or defect
  ratesperformance and function,wear,Endurance
  ability,after sales service
• 4-Customer service and flexibility-Change
  production process,use of CADCAM,reduction of
  work through JIT,increase in production capacity
TOP COMPETITIVE
            PRIORITIES
•   1-Conformance quality
•   2-Product reliability
•   3-On-time-delivery
•   4-Low price
•   5-Fast delivery
•   6-Performance quality
•   7-Speedy new product introduction
RECENT TRENDS
• Trends which demand considerable attention in
  business since they influence planning and
  decision making .Many are related to global
  competition and the impact it has on
  manufacturing firms
• 1-GLOBAL MARKET PLACE-WTO led to an
  agreement among member nations to open their
  economies,reduce tariffs and subsidies ,which has
  resulted in level of competition throughout the
  world
RECENT TRENDS(contd.)
• 2-OPERATIONSMANUFACTURING
  STRATEGY-More and more manufacturing are
  now realizing the importance of operations
  strategy and relating the same to overall business
  strategy
• 3-TOTAL QUALITY MANAGEMENT-Here the
  entire organization is committedinvolved in
  continuous improvement of goods and
  services.Key features are Team approach,problem
  solving etc
RECENT TRENDS (contd.)
• 4-TIME REDUCTION-Time reduction is being
  achieved in processing,information
  retrieval,product design and response to customer
  complaints
• 5-TECHNOLOGY-Technological advances have
  led to new products and processes.Computer
  technology applications include Product
  design,product features,process sing
  technology,information processing and
  communications
RECENT TRENDS (contd.)
• 6-FLEXIBILITY-The ability to adapt
  quickly to changes in the mix of products
  demanded and in product design has
  become a major competitive strategy
• 7-WORKER INVOLVEMENT-A key to
  worker involvement in the use of teams of
  workers ,who solve problems and make
  decisions on a consensus basis
RECENT TRENDS(contd.)
• 8-RE-ENGINEERING-Reengineering
  focuses on improving processes such as
  steps required to fill a customer,s request
• 9-ENVIRONMENTL ISSUES-World class
  producers adopt the policy of
  “environmentally responsible
  manufacturing” means reducing
  waste,pollution control,waste disposal etc
RECENT TRENDS(contd.)
• 10-CORPORTE DOWNSIZING-in order to face
  competition and improve profits,world class
  producers are reducing their Labour force
• 11-SUPPLY CHAIN MANAGEMENT-To
  remain competitive ,the world class producers are
  concentrating in managing supply chain efficiently
• 12-LEAN PRODUCTION-Lean production
  systems are those that use minimal resources to
  produce high volumehigh quality high variety
  goods
GLOBAL CORPORTIONS
• Characteristics of Global corporation
• i-Facilitiesplants are located world wide
• ii-Componentspartsservices are sourced on a
  global basis
• iii-Global product designprocess technology are
  used
• iv-Process technology is standardized
• v-Demand of products is considered world wide
• vi-LogisticsInventory control systems are global
  in nature
ATTRIBUTES OF
    EXCELLENT COMPANIES
•   i-A bias for action
•   ii-Close to the customer
•   iii-Autonomy and entrepreneurship
•   iv-Productivity through people
•   v-Hands –on,value-driven
•   vi-Stick to the knitting
•   vii-Simple form,lean staff
REQUIREMENT OF
           EXCELLENCE
• i-EXTERNL QUALITY-Value added
  performance exceeding customer
  expectations.Means repeat sales,warranty return
  rates,independent customer satisfaction
  surveys,complaints,service wait time etc
• ii-INTERNAL QUALITY-Defect free
  processes,means yields,defect rates,error
  rates,process capabilities ,percentage of processes
  with fail safe mechanismsprocedures
Requirement of
           excellence(contd.)
• iii-DEPENDIBILITY-Ensure adherence to
  promise,means on-time delivery to
  customer,timely deliveries from suppliers
• iv-RESOURCE USE-Eliminate waster and non-
  value added steps,means labour productivity
  ratio,inventory turnover,output rates
• v-FLEXIBILITY-Abilityresponse to customer
  changes quickly,means time to bring new
  product,customer order lead time,setup times etc
Requirement of
           excellence(contd.)
• vi-HUMAN RESOURCE IMPROVEMENT-
  Employees,customers,suppliers are the most
  important and valuable assets,means effective
  training,suggestion schemes,attendance rates etc
• vii-INNOVTION-Advancing in the application of
  productprocess technology without waste,means
  time to market,product feature comparisons with
  competitors,number of patents ,percentage of
  product line turnover
Requirement of
           excellence(contd.)
• vii-ENVIRONMENTAL SOUNDNESS-Business
  operations without damage to the
  environment.Means levels of
  effluentsemissions,recycling percentage,accident
  rate etc
• viii-FINANCIAL RESULTS-Rate of return
  ensuring satisfaction by Financial
  supporters.Means Profit & Loss
  statement,financial ratios,trends on actual costs
Comparison of performance
• Five ways to make comparisons
• 1-STANDARDS-Means comparison with
  accepted norms
• 2-PRIOR PERFORMANCE-Past internally data
  can be complied
• 3-CUSTOMER EXPECTATIONS-External
  performance measurement
• 4-SIMILAR OPERATIONS-Comparisons with
  world class competitors
• 5-ULTIMTE STANDATDS-Set the ultimate goal
  of “Zero error” standard
Factors of excellence of world
         class companies
• i-Strategy & culture
• ii-Fix new skills among
  managersexecutives
• iii-Creativity and innovation
• iv-Adaptive to innovative changes
• v-Customeremployee orientation
• vi-People oriented recognitionreward
  system
Factors of excellence of world
     class companies(contd.)
• vii-Team work,group activities,employee
  empowerment
• viii-Transformation oriented leadership-Leaders
  led & inspire change
• ix-Belief in quality,discipline and result
  orientation
• x-Prevention orientation and belief in never
  ending improvements (Kaizen)
• xi-Total quality management orientation
The path to becoming world class
Drive performance using peopletechnology
Leadership defines and communicates the
  goalstasks
Employees must be empowered to apply their skills
  for efficient operations
Technology is the means to transform raw materials
  into saleable products.
Technology supported with proper procedures and
  trainedmotivated personnel can ensure success
BUSINESS DRIVERS
• Things which drive improvements
• i-Quality-Process capabilityperformance
  indices and refers to product which meets
  customers needs
• ii-First pass first quality-Refers to making
  product right first time
• iii-Throughput-Ensure efficient production
  cycle time
BUSINESS
        DRIVERS(CONTD.)
• iii-Uptime-Ensure equipment availability at
  full rate
• iv-Cycle time-this is the elapsed time
  between receiving raw materials and
  shipping corresponding product
•              The business drivers as
  indicated above are the elements of of an
  appropriate control system
Time based competition
• Using JIT(lean manufacturing) for time based
  competition
• BENEFITS
• i-Customers will pay for quick response.Suppliers
  will be benefited with fast delivery.Ensures faster
  growth and greater market share
• ii-The re-engineered processes increase
  productivity,high quality & costs as comparable to
  the competitors
Becoming a time based
            competitors
• i-It focuses on processes & not functions
• ii-Managers are evaluated and rewarded on the
  basis of their time metrics
• iii-Just in Time is the key to speed on the shop
  floor
• iv-Reengineering based on JIT concept is the key
  to speed in all the firm,s processes.Reengineering
  is the engine of Time based competition
WORLD CLASS SUPPLIERS
• Choosing suppliers-While
  selecting,flexibility,location,price,product
• service changes,reputation and financial
  stability re key considerations
• Evaluating sources of supply-must be
  evaluated periodically on
  price,speed,responses to changes
WORLD CLASS
          SUPPLIERS(contd.)
• Supplier audits-periodic audits of suppliers
  provide a means of keeping up-to-date,suppliers
  productionservice,quality,delivery issues etc
• Supplier certification-supplier certification
  examines the policiescapabilities.If supplier
  exceeds the expectations,they are certified as long
  term relationship suppliers and sometimes called
  ‘World class suppliers’
Supplier partnership
• World class suppliers are viewed as partners of
  world class manufactures and build long term
  relationship,which could lead to improved
  competitiveness in
• i-Cost reduction in purchaseproduction costs
• ii-Reduction in transportationinventory costs
• iii--Improvement in product designqualitynew
  productsprocesses
• iv-Reduction in throughput time
• v-Improvement in customer satisfaction
WORLD CLASS
     CUSTOMERS(BUYERS)
• World class customers(buyers) are characterized
  by seven drivers of partnering with suppliers
• 1-Excellent quality
• 2-Timeliness
• 3-Flexibility
• 4-Superior communication
• 5-Continuous improvement
• 6-Collaborative attitude
• 7-Trust
Characteristics of a good
     customer towards supplier
• i-Awareness attractiveness to their suppliers
  needs
• ii-Record of keeping promises
• iii-Willingness to share plansinformation with
  suppliers
• iv-Willingness to explore processproduct
  improvement
• v-Solving suppliers problems expeditiously
• vi-Active feedback from suppliers and taking
  corrective action,wherever required
Benefits achieved by being world
  class customers in supplier
           partnership
• i-Cost saving-Better communication with
  suppliers lowers administrative costs
• ii-Time saving-By giving early
  information,suppliers lead time can be reduced
• iii-Better productsProcesses-Based on suppliers
  experienceexpertise,he can offer better
  productsProcesses
• iv-Improved customer organization and
  professional skills-By spending time with
  suppliers,customers learn new communication
  skillsaspects of their organization
Today,s global business
              conditions
• For developing business strategy ,it is essential to
  know the factors affecting today's global business
  conditions
• i-Reality of global competition
• ii-Quality,customer service & cost challenges of
  the supplier firm
• iii-Rapid expansion of advanced production
  technology
• iv-Scarcity of production resources
• v-Social-responsibility issues
Competitive priorities of
             production
•   #-Low production costs
•   #-Fast and on-time delivery
•   #-High quality productservices
•   #-Customer services and flexibility
•         After setting competitive priorities
    ,operations strategy must determine the required
    production system needed to provide the priorities
    for the productservices
Performance of world class
          manufacturers
• Areas of productionoperation management
  relevant to achieve competitive advantage
• 1-Manufacturingoperations strategy-
  Requires long term business plans such s
  personnel training & development,market
  development,new productservice
  development,high tech. Production
  process,R&D
Performance of world class
           manufacturers
• Characteristics of world class producers
• i-Customer first
• ii-Introduce new productsservices faster
• iii-Ensure Total Quality Management
• iv-High labour productivityLow production costs
• v-Shop globally for supplies
• vi-leanflexible organization with balanced
  inventory
• V-Develop specialized focus production facilities
• vi-Encourage strategic alliancesjoint ventures to
Performance of world class
       manufacturers(contd.)
• 2-Forecasting in operations management-
  Forecasting experts maintain sophisticated
  computer software and get data such as market
  research,industry trade association data etc to
  ensure best long range estimate of sales of
  newexisting products in global market and
  monitor performance of forecasts
• The effective forecasting of production
  capacity,size of work force,quantity of materials
  purchased ,inventory levels and working capital
  requirement drives a closely managed production
  planning system
Performance of world class
       manufacturers(contd.)
• 3-DesigningDeveloping products and
  production processes-World class producers plan
  and design their production processes with
  specific capabilities that are matched with the
  competitive priorities of their business strategies
• High product quality,high production
  flexibility,low product cost and high customer
  service are the major strengths.To achieve they
  use various technologies such as using
  CADCAM,continuous improvement,improving
  flexibility & reducing costs by redesigning
  production processesdoing automation etc
Performance of world class
      manufacturers(contd.)
• 4-Production technology-selection and
  management .World class producers view
  advanced production technology as a competitive
  weapon and do the following
• i-Designing products to be ‘automation
  friendly’,standardization of partsincreasing
  quality of components
• ii-Using CADCAM
• iii-Adopting Flexible manufacturing
  system,automated storage and retrieval
  systems,automated assembly etc
Performance of world class
        manufactures(contd.)
• iv-Using computer controlled machines
• v-Adopting flexible production systems
• vi-Adopting computer integrated system
• vii-Ensure better customer service,reduced costs
  and improve flexibility
• vii-Using automation processes with justification
• vii-Training and building teams using new
  production technologyprocesses
Performance of world class
        manufactures(contd.)
• 5-Long range capacity planning and facility
  location-World class producers carry out long
  range business planning considering expected
  changes in product life cycle and involve world
  wide search for location of Plants
• 6-Facility Layout-World class producers strive
  for flexibility in their layouts ensuring change in
  production ratesdesigns quickly and use
  Automated Layout Design Program,Computerized
  Relationship Layout Planning,Computerized
  Relative allocation of facilities techniques for
  layout designing
Performance of world class
      manufacturers(contd.)
• 7-Aggregate planning and Master
  Production Scheduling-World class
  producers develop strategies that enable
  them to capture increasing share of world
  markets and use current trends approaches
  to achieve increased market share,high
  product quality,low production costs and
  high customer satisfaction
Performance of world class
       manufactures(contd.)
• 8-Independent demand inventory system-’Pull
  system’ of production planning and control and
  procurement through EOQRe-order level of
  efficient Inventory system is used
• 9-Resource Requirement planning-World class
  producers have incorporated MRP-II and ERP
  system over a period of time ensuring continuous
  improvements towards improved
  productivity,lower costs and better customer
  service
Performance of world class
       manufacturers(contd.)
• 10-Shop floor planning and control in
  manufacturing-In this type of production,world
  class producers have effective MRP-II systems in
  place which provide near real time information for
  companies,their supplierscustomers.These
  systems facilitate meeting customer delivery
  promises,optimal loading of shops,low production
  costs and high product quality
Performance of world class
      manufacturers(contd.)
• 11-Planning and scheduling operations-World
      Pl
  class producers offering services have adopted
  advancedwell known planning,analyzing and
  controlling approaches and have recognized the
  unique properties of service operations and have
  developed novel management approaches for
  service operations
• 12-Just In Time manufacturing-Elimination of
  waste,enforced problem solving,building team
  work,TQM,parallel processing,Kanban production
  control and JIT purchasing are essential in world
  class manufacturing
Performance of world class
       manufacturers(contd.)
• 13-Supply Chain Management-World class
  producers are forming partnership with suppliers
  to expedite production of products of perfect
  quality and use computers for solving complicated
  logistic related issues
• 14-Productivity,Team work and
  Empowerment-World class producers hire
  workers who have problem solving abilities and
  train them in multiple skills.Workers are educated
  and empowered so that they can work in teams to
  solve production problems and respond to
  customer needs also.
Performance of world class
      manufacturers(contd.)
• 15-Quality Management-World class
  manufacturers are committing tremendous
  resources to put in place TQM program aimed at
  continuous quality improvement
• 16-Quality Control-World class companies have
  comprehensive proactive total quality
  management programs with specific projects
  aimed at improving quality to meet customer
  expectations
Performance of world class
      manufacturers(contd.)
• 17-Maintenance Management and Reliability-
  World class producers give much of responsibility
  for repairs and preventive maintenance to workers
  and they are made to feel that they own machines
  and ensure avoid major breakdowns by ensuring
  regular preventive maintenance.They also
  implement JIT system to increase flexibility in
  production and implement a sophisticated
  preventive maintenance program
Path of world class
               Manufacturing
•   i-Fewer suppliers
•   ii-Focused factories
•   iii-Simplification & variety reduction
•   iv-Scheduling to a rate of production
•   v-Fewer storage racks
•   vi-Frequent deliveries by suppliers
•   vii-Smaller manufacturing plants
•   viii-Minimum material handling
•   ix-Less paperwork
•   x-Fewer inspectors
World Class manufacturing
            Strategy
• The world class companies are required to build
  an interface between marketing and
  manufacturing,and follow actions such as
• i-Invest more in R&D,emphasize less on short
  term payoff.
• ii-Improve manufacturing capability by investing
  in peopleequipments.
• iii-Remove communication barriers.
• iv-Labor force is to be murtured.
• v-Build quality at design stage,emphasize on
  process innovations.
World Class Service Delivery
• Characteristics-Service excellence,Delight
  customers,Expand customer expectations to a
  level, competitors can not fill
• Service quality-Raises customer
  expectations,seeks challenges,improves
  continuously
• New technology-Source of first mover to gain
  advantage
• Work force-Innovative,create procedures
• First line management-Is listened to by top
  management as a source of new ideas
World Class Performance
• Means winning the competitive race,running
  fastersmarter than the competition.
• Starts with through understanding of ‘current
  internal environment as well as its ‘strengths and
  weaknesses’
• If Total Quality Management is not
  enthusiastically promotedsupported by
  management,it will not be able to achieve ‘Quality
  at source”
World Class Performance(contd.)
• Strategy on the road to Excellence-
  Manufacturing strategy starts with an
  assessment of where a firm is now and a
  vision of where it wants to be in future in
  key indicators such as on-time delivery to
  customer requirements,manufacturing lead
  time,inventory turns,quality,new product
  introduction time,supplier
  relations,employee involvement ,flexibility
World Class Performance(contd.)
• Vision-Answer questions with ‘What-if’ for a
  firm looking forward 35 years hence i.e. reduce
  manufacturing cycle time by 70%,quality costs are
  reduced by 25% etc
• Control-Having assessed its strengths and
  weaknesses and defined its vision,the company
  must gain control over the current environment by
  developing process to ensure integrated planning
  from top to bottom.Requires education and
  training to all employees in systems,policies and
  procedures to support the user and process.
World Class Performance(contd.)
• Simplification-Ensure continuous
  improvement through team work on
  changeover times,factory layout,restrictive
  job classifications,supplier relations etc
• Automation-Computer Integrated
  Manufacturing,MRP-ii,JIT,Total Quality
  control,Focused factories etc are supportive
  of world class factories
World Class Companies in 21st
            Century
• Previous Decade(1990-2000)-Competitive
  priorities were Low price,New product
  introduction speed,Quality,Delivery speed,Product
  reliability
• Present Decade(2000 onwards)-Competitive
  priorities ‘high quality at low price’,means high
  quality,timely availability and removal of non-
  value adding wastes.requires finding external
  partners ,who can perform valued function,with
  advanced communications and efficient logistics
Customer focused Principals
• 1-Team up with customers,organize by families of
  customers to products
• 2-Capture and apply customer,competitive and
  best practice information
• 3-Dedicate to continual,rapid improvement in
  quality,response time,flexibility and value
• 4-Frontline employees involved in change and
  strategic planning-to achieve unified purpose
Customer focused
           principals(contd.)
• 5-Cut to the few best components,operations and
  suppliers
• 6-Cut flow time,distance,start up,and changeover
  times all along the chain
• 7-Operate close to customer,s rate of use or
  demand
• 8-Continuously enhance human resources through
  cross training,job,and career path rotation and
  improvements in health,safety and security
Customer focused
            principles(contd.)
• 9-Expand the variety of rewards ,recognition,pay
  and celebration-to match the expanded variety of
  employee contribution
• 10-Continuously reduce variation and mishaps
• 11-Front line teams record and own process data
  at the work place
• 12-Control root causes of cost and
  performance,thereby reducing internal transactions
  and reporting,simplify external communications
Customer focused
           principles(contd.)
• 13-Align performance measures with universal
  customer requires-quality,speed,flexibility and
  value
• 14-Improve present equipment and human work
  before considering new equipment and automation
• 15-Seek simple ,flexible,moveable,low
  cost,readily available equipment and work
  facilities-in multiples,one for each
  productcustomer family
• 16-Promote,market and sell your organization,s
  increasing capability and competence-every
  improvement made.
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World Class Manufacturing

  • 1. CHAPTER-2 • WORLD CLASS MANUFACTURING • AN OVERVIEW
  • 2. Towards 21st Century management of mfg. companies • Mode • Assessment • i-Management by Edict Inconsistent,wasteful • ii-Management by Inconsistentquicker,wasteful procedure of talent • iii-Management by High level wisdom,limits • Policies empowerment • iv-Management by Principals Customer focused,employee driven,data based
  • 3. Customer based principals • 1-Team up with customers,organize by families of customers to products • 2-Capture and apply customer,competitive and best practice information • 3-Dedicate to continual,rapid improvement in quality,response time,flexibility and value • 4-Frontline employees involved in change and strategic planning • 5-Cut to few best components,operations and suppliers
  • 4. GLOBAL MARKET • Markets are becoming more global in nature • Consumer demand is more homogenized on international basis • An international business organization is a firm tht engages in cross-border transactions • When operating in global market,a traditional company is at a “competitive disadvantage”because of inadequate products,wrong scale of operations,wrong way to produce and wrong way to market its products
  • 5. GLOBAL MARKET(contd.) • This has resulted in emergence of following • 1-”Multinational corporation”-is a firm with extensive involvement in international business • 2-”Global company”is a firm that integrates operations from different countries,considers world s single market • 3-”Transnational company” is a firm that seeks to combine the benefits of global scale efficiencies with benefits of local responsiveness
  • 6. GLOBAL MARKET (contd.) • Demand for products is considered on a worldwide .This results into higher economies of scale and lower costs. • Logistics and inventory control systems are global in nature • Within the global arena ,competition has become intense due to greater number of players and existence of opportunities
  • 7. GLOBAL MARKET(CONTD.) • The world wide customers evaluate quality of productsservices from various dimensions such as performance,features,reliability,serviceability,dura bility,appearance ,customer service and safety • This calls for improvement in productsservices to meet the expectations of customer • Companies who have excelled on the international level are referred as “World class companies” • “World class company “means that each product service would be considered “best in class” by its customers.
  • 8. BECOMING WORLD CLASS • World class performance comes from world class practice,which is created by world class management • Quality is no longer viewed as an act of faith but as a contributor to business results • In going beyond quality ,the focus should provide ,new challenges and new targets and reinforce what has already been achieved
  • 9. BECOMING WORLD CLASS (CONTD.) • QUALITY MATURITY PHASES- • 1-Management decides they need quality • 2-Management learnstalks about quality • 3-Quality begins to be seen as a reality • 4-Embedding the quality process • 5-CEO establishes benchmarks from external sources and drives the organization • 6-Quality process and business objectives get integrated • 7-The company has become lean,fast and capable .means “World class”
  • 10. GLOBALISATION OF PRODUCTION • Objectives • 1-Reduce costs • 2-Reduce risks • 3-Improve supply chain • 4-Provide better goods and services • 5-Attract new markets • 6-Learn to improve operations • 7-Attract and retain global talent
  • 11. WORLD CLASS MANUFCTURING • Factors affecting global business conditions • 1-Reality of global competition • 2-Quality,customer & cost challenges • 3-Rapid expansion of advanced manufacturing technology • 4-Continued growth and importance of service sector • 5-Scarcity of production resources • 6-Social responsibility issues
  • 12. Global competition reality • India,s liberalized economic policy started in 1992 • Means Liberalization,Privatization & globalization • Indian manufacturers face tough competition from foreign companies • Also inflation,fluctuating currency,turbulent interest rates,volatility in international stock market,huge national debts of many countries,trade imbalance etc have created complex financial conditions in global businesses • Global business in future will have the objective of “perfect product” & “service quality”
  • 13. TQM IN WORLD CLASS MANUFCTURING • Many smalllarge companies have adopted total quality management as a way of life • They focus on customers needs , and structure their organization to deliver to these needs • Organization culture gets changed to achieve perfect quality • To respond to customer,s needs ,many firms hve adopted TQM,ISO 9000 and JIT manufacturing to ensure reduced inventory costs and flexible operations
  • 14. AUTOMATION IN PRODUCTIONSERVICE OPERATIONS • i-Computer aided design(CAD)-Specialized softwarehardware for design of products • ii-Computer aided manufacturing(CAM)- Translation of CAD information in automated production machinery • iii-Flexible manufacturing systems(FMS) • Computers give instructions,robots handle parts and materialsmachines setting are changed automatically to produce different products
  • 15. Automation in productionservice operations(contd.) • iv-Automated storage and retrieval systems(ASRS)-Computer controlled warehouses.Includes automatic placement removal of parts as also automatic transportation of parts • v-Automatic identification system(AIS)-Bar coding,radio frequencyoptical characters are designed to present data and are read by scanners that transmit data to computers
  • 16. ISSUES • 1-Growth of service sector-Service and manufacturing sectors are inter-related • 2-Scarcity of production resources-Scarcity of various raw materials,personal skills require judicious allocation of resources • 3-Social impacts • i-Environmental impact-needs concern about about waste disposal,airwaterground pollution etc • ii-Employee impact-Labor shortages,statefederal laws etc require development of fair treatment
  • 17. GLOBAL COMPETITIVENESS • “Competitiveness” can be defined as the long term viability of firm and is also measured by its “market share” or its “profitability” • “Competitiveness” of a nation in the sense of its aggregate competitive success in all markets • DistinctiveCore competencies represent competitive advantage in capturing markets • Examples of DistinctiveCore competency are automated production technology,skilleddedicated work force,ability to bring new products in production,talented work force etc
  • 18. Competitive priorities of Manufacturing • 1-line production costs-Redesign of products,new production technology,increased rate of production,Reduction of scrap,reduction of inventories • 2-Delivering performance-higher finished goods inventory,Faster production rates,Quicker shipping methods,realistic promises,Better control of production orders,Better information system
  • 19. Competitive priorities of manufacturing(contd.) • 3-High quality productServices-improve productservices appearancemalfunction or defect ratesperformance and function,wear,Endurance ability,after sales service • 4-Customer service and flexibility-Change production process,use of CADCAM,reduction of work through JIT,increase in production capacity
  • 20. TOP COMPETITIVE PRIORITIES • 1-Conformance quality • 2-Product reliability • 3-On-time-delivery • 4-Low price • 5-Fast delivery • 6-Performance quality • 7-Speedy new product introduction
  • 21. RECENT TRENDS • Trends which demand considerable attention in business since they influence planning and decision making .Many are related to global competition and the impact it has on manufacturing firms • 1-GLOBAL MARKET PLACE-WTO led to an agreement among member nations to open their economies,reduce tariffs and subsidies ,which has resulted in level of competition throughout the world
  • 22. RECENT TRENDS(contd.) • 2-OPERATIONSMANUFACTURING STRATEGY-More and more manufacturing are now realizing the importance of operations strategy and relating the same to overall business strategy • 3-TOTAL QUALITY MANAGEMENT-Here the entire organization is committedinvolved in continuous improvement of goods and services.Key features are Team approach,problem solving etc
  • 23. RECENT TRENDS (contd.) • 4-TIME REDUCTION-Time reduction is being achieved in processing,information retrieval,product design and response to customer complaints • 5-TECHNOLOGY-Technological advances have led to new products and processes.Computer technology applications include Product design,product features,process sing technology,information processing and communications
  • 24. RECENT TRENDS (contd.) • 6-FLEXIBILITY-The ability to adapt quickly to changes in the mix of products demanded and in product design has become a major competitive strategy • 7-WORKER INVOLVEMENT-A key to worker involvement in the use of teams of workers ,who solve problems and make decisions on a consensus basis
  • 25. RECENT TRENDS(contd.) • 8-RE-ENGINEERING-Reengineering focuses on improving processes such as steps required to fill a customer,s request • 9-ENVIRONMENTL ISSUES-World class producers adopt the policy of “environmentally responsible manufacturing” means reducing waste,pollution control,waste disposal etc
  • 26. RECENT TRENDS(contd.) • 10-CORPORTE DOWNSIZING-in order to face competition and improve profits,world class producers are reducing their Labour force • 11-SUPPLY CHAIN MANAGEMENT-To remain competitive ,the world class producers are concentrating in managing supply chain efficiently • 12-LEAN PRODUCTION-Lean production systems are those that use minimal resources to produce high volumehigh quality high variety goods
  • 27. GLOBAL CORPORTIONS • Characteristics of Global corporation • i-Facilitiesplants are located world wide • ii-Componentspartsservices are sourced on a global basis • iii-Global product designprocess technology are used • iv-Process technology is standardized • v-Demand of products is considered world wide • vi-LogisticsInventory control systems are global in nature
  • 28. ATTRIBUTES OF EXCELLENT COMPANIES • i-A bias for action • ii-Close to the customer • iii-Autonomy and entrepreneurship • iv-Productivity through people • v-Hands –on,value-driven • vi-Stick to the knitting • vii-Simple form,lean staff
  • 29. REQUIREMENT OF EXCELLENCE • i-EXTERNL QUALITY-Value added performance exceeding customer expectations.Means repeat sales,warranty return rates,independent customer satisfaction surveys,complaints,service wait time etc • ii-INTERNAL QUALITY-Defect free processes,means yields,defect rates,error rates,process capabilities ,percentage of processes with fail safe mechanismsprocedures
  • 30. Requirement of excellence(contd.) • iii-DEPENDIBILITY-Ensure adherence to promise,means on-time delivery to customer,timely deliveries from suppliers • iv-RESOURCE USE-Eliminate waster and non- value added steps,means labour productivity ratio,inventory turnover,output rates • v-FLEXIBILITY-Abilityresponse to customer changes quickly,means time to bring new product,customer order lead time,setup times etc
  • 31. Requirement of excellence(contd.) • vi-HUMAN RESOURCE IMPROVEMENT- Employees,customers,suppliers are the most important and valuable assets,means effective training,suggestion schemes,attendance rates etc • vii-INNOVTION-Advancing in the application of productprocess technology without waste,means time to market,product feature comparisons with competitors,number of patents ,percentage of product line turnover
  • 32. Requirement of excellence(contd.) • vii-ENVIRONMENTAL SOUNDNESS-Business operations without damage to the environment.Means levels of effluentsemissions,recycling percentage,accident rate etc • viii-FINANCIAL RESULTS-Rate of return ensuring satisfaction by Financial supporters.Means Profit & Loss statement,financial ratios,trends on actual costs
  • 33. Comparison of performance • Five ways to make comparisons • 1-STANDARDS-Means comparison with accepted norms • 2-PRIOR PERFORMANCE-Past internally data can be complied • 3-CUSTOMER EXPECTATIONS-External performance measurement • 4-SIMILAR OPERATIONS-Comparisons with world class competitors • 5-ULTIMTE STANDATDS-Set the ultimate goal of “Zero error” standard
  • 34. Factors of excellence of world class companies • i-Strategy & culture • ii-Fix new skills among managersexecutives • iii-Creativity and innovation • iv-Adaptive to innovative changes • v-Customeremployee orientation • vi-People oriented recognitionreward system
  • 35. Factors of excellence of world class companies(contd.) • vii-Team work,group activities,employee empowerment • viii-Transformation oriented leadership-Leaders led & inspire change • ix-Belief in quality,discipline and result orientation • x-Prevention orientation and belief in never ending improvements (Kaizen) • xi-Total quality management orientation
  • 36. The path to becoming world class Drive performance using peopletechnology Leadership defines and communicates the goalstasks Employees must be empowered to apply their skills for efficient operations Technology is the means to transform raw materials into saleable products. Technology supported with proper procedures and trainedmotivated personnel can ensure success
  • 37. BUSINESS DRIVERS • Things which drive improvements • i-Quality-Process capabilityperformance indices and refers to product which meets customers needs • ii-First pass first quality-Refers to making product right first time • iii-Throughput-Ensure efficient production cycle time
  • 38. BUSINESS DRIVERS(CONTD.) • iii-Uptime-Ensure equipment availability at full rate • iv-Cycle time-this is the elapsed time between receiving raw materials and shipping corresponding product • The business drivers as indicated above are the elements of of an appropriate control system
  • 39. Time based competition • Using JIT(lean manufacturing) for time based competition • BENEFITS • i-Customers will pay for quick response.Suppliers will be benefited with fast delivery.Ensures faster growth and greater market share • ii-The re-engineered processes increase productivity,high quality & costs as comparable to the competitors
  • 40. Becoming a time based competitors • i-It focuses on processes & not functions • ii-Managers are evaluated and rewarded on the basis of their time metrics • iii-Just in Time is the key to speed on the shop floor • iv-Reengineering based on JIT concept is the key to speed in all the firm,s processes.Reengineering is the engine of Time based competition
  • 41. WORLD CLASS SUPPLIERS • Choosing suppliers-While selecting,flexibility,location,price,product • service changes,reputation and financial stability re key considerations • Evaluating sources of supply-must be evaluated periodically on price,speed,responses to changes
  • 42. WORLD CLASS SUPPLIERS(contd.) • Supplier audits-periodic audits of suppliers provide a means of keeping up-to-date,suppliers productionservice,quality,delivery issues etc • Supplier certification-supplier certification examines the policiescapabilities.If supplier exceeds the expectations,they are certified as long term relationship suppliers and sometimes called ‘World class suppliers’
  • 43. Supplier partnership • World class suppliers are viewed as partners of world class manufactures and build long term relationship,which could lead to improved competitiveness in • i-Cost reduction in purchaseproduction costs • ii-Reduction in transportationinventory costs • iii--Improvement in product designqualitynew productsprocesses • iv-Reduction in throughput time • v-Improvement in customer satisfaction
  • 44. WORLD CLASS CUSTOMERS(BUYERS) • World class customers(buyers) are characterized by seven drivers of partnering with suppliers • 1-Excellent quality • 2-Timeliness • 3-Flexibility • 4-Superior communication • 5-Continuous improvement • 6-Collaborative attitude • 7-Trust
  • 45. Characteristics of a good customer towards supplier • i-Awareness attractiveness to their suppliers needs • ii-Record of keeping promises • iii-Willingness to share plansinformation with suppliers • iv-Willingness to explore processproduct improvement • v-Solving suppliers problems expeditiously • vi-Active feedback from suppliers and taking corrective action,wherever required
  • 46. Benefits achieved by being world class customers in supplier partnership • i-Cost saving-Better communication with suppliers lowers administrative costs • ii-Time saving-By giving early information,suppliers lead time can be reduced • iii-Better productsProcesses-Based on suppliers experienceexpertise,he can offer better productsProcesses • iv-Improved customer organization and professional skills-By spending time with suppliers,customers learn new communication skillsaspects of their organization
  • 47. Today,s global business conditions • For developing business strategy ,it is essential to know the factors affecting today's global business conditions • i-Reality of global competition • ii-Quality,customer service & cost challenges of the supplier firm • iii-Rapid expansion of advanced production technology • iv-Scarcity of production resources • v-Social-responsibility issues
  • 48. Competitive priorities of production • #-Low production costs • #-Fast and on-time delivery • #-High quality productservices • #-Customer services and flexibility • After setting competitive priorities ,operations strategy must determine the required production system needed to provide the priorities for the productservices
  • 49. Performance of world class manufacturers • Areas of productionoperation management relevant to achieve competitive advantage • 1-Manufacturingoperations strategy- Requires long term business plans such s personnel training & development,market development,new productservice development,high tech. Production process,R&D
  • 50. Performance of world class manufacturers • Characteristics of world class producers • i-Customer first • ii-Introduce new productsservices faster • iii-Ensure Total Quality Management • iv-High labour productivityLow production costs • v-Shop globally for supplies • vi-leanflexible organization with balanced inventory • V-Develop specialized focus production facilities • vi-Encourage strategic alliancesjoint ventures to
  • 51. Performance of world class manufacturers(contd.) • 2-Forecasting in operations management- Forecasting experts maintain sophisticated computer software and get data such as market research,industry trade association data etc to ensure best long range estimate of sales of newexisting products in global market and monitor performance of forecasts • The effective forecasting of production capacity,size of work force,quantity of materials purchased ,inventory levels and working capital requirement drives a closely managed production planning system
  • 52. Performance of world class manufacturers(contd.) • 3-DesigningDeveloping products and production processes-World class producers plan and design their production processes with specific capabilities that are matched with the competitive priorities of their business strategies • High product quality,high production flexibility,low product cost and high customer service are the major strengths.To achieve they use various technologies such as using CADCAM,continuous improvement,improving flexibility & reducing costs by redesigning production processesdoing automation etc
  • 53. Performance of world class manufacturers(contd.) • 4-Production technology-selection and management .World class producers view advanced production technology as a competitive weapon and do the following • i-Designing products to be ‘automation friendly’,standardization of partsincreasing quality of components • ii-Using CADCAM • iii-Adopting Flexible manufacturing system,automated storage and retrieval systems,automated assembly etc
  • 54. Performance of world class manufactures(contd.) • iv-Using computer controlled machines • v-Adopting flexible production systems • vi-Adopting computer integrated system • vii-Ensure better customer service,reduced costs and improve flexibility • vii-Using automation processes with justification • vii-Training and building teams using new production technologyprocesses
  • 55. Performance of world class manufactures(contd.) • 5-Long range capacity planning and facility location-World class producers carry out long range business planning considering expected changes in product life cycle and involve world wide search for location of Plants • 6-Facility Layout-World class producers strive for flexibility in their layouts ensuring change in production ratesdesigns quickly and use Automated Layout Design Program,Computerized Relationship Layout Planning,Computerized Relative allocation of facilities techniques for layout designing
  • 56. Performance of world class manufacturers(contd.) • 7-Aggregate planning and Master Production Scheduling-World class producers develop strategies that enable them to capture increasing share of world markets and use current trends approaches to achieve increased market share,high product quality,low production costs and high customer satisfaction
  • 57. Performance of world class manufactures(contd.) • 8-Independent demand inventory system-’Pull system’ of production planning and control and procurement through EOQRe-order level of efficient Inventory system is used • 9-Resource Requirement planning-World class producers have incorporated MRP-II and ERP system over a period of time ensuring continuous improvements towards improved productivity,lower costs and better customer service
  • 58. Performance of world class manufacturers(contd.) • 10-Shop floor planning and control in manufacturing-In this type of production,world class producers have effective MRP-II systems in place which provide near real time information for companies,their supplierscustomers.These systems facilitate meeting customer delivery promises,optimal loading of shops,low production costs and high product quality
  • 59. Performance of world class manufacturers(contd.) • 11-Planning and scheduling operations-World Pl class producers offering services have adopted advancedwell known planning,analyzing and controlling approaches and have recognized the unique properties of service operations and have developed novel management approaches for service operations • 12-Just In Time manufacturing-Elimination of waste,enforced problem solving,building team work,TQM,parallel processing,Kanban production control and JIT purchasing are essential in world class manufacturing
  • 60. Performance of world class manufacturers(contd.) • 13-Supply Chain Management-World class producers are forming partnership with suppliers to expedite production of products of perfect quality and use computers for solving complicated logistic related issues • 14-Productivity,Team work and Empowerment-World class producers hire workers who have problem solving abilities and train them in multiple skills.Workers are educated and empowered so that they can work in teams to solve production problems and respond to customer needs also.
  • 61. Performance of world class manufacturers(contd.) • 15-Quality Management-World class manufacturers are committing tremendous resources to put in place TQM program aimed at continuous quality improvement • 16-Quality Control-World class companies have comprehensive proactive total quality management programs with specific projects aimed at improving quality to meet customer expectations
  • 62. Performance of world class manufacturers(contd.) • 17-Maintenance Management and Reliability- World class producers give much of responsibility for repairs and preventive maintenance to workers and they are made to feel that they own machines and ensure avoid major breakdowns by ensuring regular preventive maintenance.They also implement JIT system to increase flexibility in production and implement a sophisticated preventive maintenance program
  • 63. Path of world class Manufacturing • i-Fewer suppliers • ii-Focused factories • iii-Simplification & variety reduction • iv-Scheduling to a rate of production • v-Fewer storage racks • vi-Frequent deliveries by suppliers • vii-Smaller manufacturing plants • viii-Minimum material handling • ix-Less paperwork • x-Fewer inspectors
  • 64. World Class manufacturing Strategy • The world class companies are required to build an interface between marketing and manufacturing,and follow actions such as • i-Invest more in R&D,emphasize less on short term payoff. • ii-Improve manufacturing capability by investing in peopleequipments. • iii-Remove communication barriers. • iv-Labor force is to be murtured. • v-Build quality at design stage,emphasize on process innovations.
  • 65. World Class Service Delivery • Characteristics-Service excellence,Delight customers,Expand customer expectations to a level, competitors can not fill • Service quality-Raises customer expectations,seeks challenges,improves continuously • New technology-Source of first mover to gain advantage • Work force-Innovative,create procedures • First line management-Is listened to by top management as a source of new ideas
  • 66. World Class Performance • Means winning the competitive race,running fastersmarter than the competition. • Starts with through understanding of ‘current internal environment as well as its ‘strengths and weaknesses’ • If Total Quality Management is not enthusiastically promotedsupported by management,it will not be able to achieve ‘Quality at source”
  • 67. World Class Performance(contd.) • Strategy on the road to Excellence- Manufacturing strategy starts with an assessment of where a firm is now and a vision of where it wants to be in future in key indicators such as on-time delivery to customer requirements,manufacturing lead time,inventory turns,quality,new product introduction time,supplier relations,employee involvement ,flexibility
  • 68. World Class Performance(contd.) • Vision-Answer questions with ‘What-if’ for a firm looking forward 35 years hence i.e. reduce manufacturing cycle time by 70%,quality costs are reduced by 25% etc • Control-Having assessed its strengths and weaknesses and defined its vision,the company must gain control over the current environment by developing process to ensure integrated planning from top to bottom.Requires education and training to all employees in systems,policies and procedures to support the user and process.
  • 69. World Class Performance(contd.) • Simplification-Ensure continuous improvement through team work on changeover times,factory layout,restrictive job classifications,supplier relations etc • Automation-Computer Integrated Manufacturing,MRP-ii,JIT,Total Quality control,Focused factories etc are supportive of world class factories
  • 70. World Class Companies in 21st Century • Previous Decade(1990-2000)-Competitive priorities were Low price,New product introduction speed,Quality,Delivery speed,Product reliability • Present Decade(2000 onwards)-Competitive priorities ‘high quality at low price’,means high quality,timely availability and removal of non- value adding wastes.requires finding external partners ,who can perform valued function,with advanced communications and efficient logistics
  • 71. Customer focused Principals • 1-Team up with customers,organize by families of customers to products • 2-Capture and apply customer,competitive and best practice information • 3-Dedicate to continual,rapid improvement in quality,response time,flexibility and value • 4-Frontline employees involved in change and strategic planning-to achieve unified purpose
  • 72. Customer focused principals(contd.) • 5-Cut to the few best components,operations and suppliers • 6-Cut flow time,distance,start up,and changeover times all along the chain • 7-Operate close to customer,s rate of use or demand • 8-Continuously enhance human resources through cross training,job,and career path rotation and improvements in health,safety and security
  • 73. Customer focused principles(contd.) • 9-Expand the variety of rewards ,recognition,pay and celebration-to match the expanded variety of employee contribution • 10-Continuously reduce variation and mishaps • 11-Front line teams record and own process data at the work place • 12-Control root causes of cost and performance,thereby reducing internal transactions and reporting,simplify external communications
  • 74. Customer focused principles(contd.) • 13-Align performance measures with universal customer requires-quality,speed,flexibility and value • 14-Improve present equipment and human work before considering new equipment and automation • 15-Seek simple ,flexible,moveable,low cost,readily available equipment and work facilities-in multiples,one for each productcustomer family • 16-Promote,market and sell your organization,s increasing capability and competence-every improvement made.
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