WORLD CLASS

MANUFACTURING
M.Tech (Production Engineering)
By :- Anuprita Bhosale
Industrial Revolution :-

Industrial revolutions occur over a period of time which completely

changed the manufacturing processes and mankind.
We have at present four industrial revolutions namely :-
1st Industrial Revolution – Industry 1.0
2nd Industrial Revolution – Industry 2.0
3rd Industrial Revolution – Industry 3.0
4th Industrial Revolution – Industry 4.0
Industrial Revolution :-
4th Industrial Revolution – Industry 4.0
5th Industrial Revolution – Industry 5.0

If current revolution emphasizes the transformation of factories

into IoT – enables smart facilities that utilize cognitive computing
and interconnect via cloud servers, Industry 5.0 is set to focus on
the return of human hands and minds into the industrial
framework means using just hands and mind , rest is just
automation.
 World Class Manufacturing :-

Adopting the I4.0 paradigm means transforming the factory into a fully interconnected environment,
where decisions can be quickly made based on reliable, accurate, precise and real-time data. However,
the impact of I4.0 is not limited to the shop floor: I4.0 is a digital revolution that is pretended to have a
global influence, unraveling the real potential of a circular economy, as well as enabling sustainable
manufacturing.
 World Class Manufacturing :-
Introduction to World Class Manufacturing:-

1- Flexible Production
2- Application of digitization, Robotics, Automation
3- Self regulating production.
4- Standardizations for the products
5- Operational Excellence
 World Class Manufacturing :-
Advantages with World Class Manufacturing:-

1- Reduction of time to market

2- Increased customization to meet the needs of individual consumers.
3- Small batch production with high quality.
4- Decentralization of decision making
5- Increased resource efficiency.
6- Technological innovations like internet, apps, AI, 3D printing etc.
 World Class Manufacturing :-

Methodology to Structure the WCM-I4.0 Matrix:-

1. Cloud Computing;
2. Cognitive Computing;
3. Internet of Things;
4. Machine-to-Machine (M2M);
5. Mobile Technologies;
6. Augmented Reality;
7. Simulation;
8. Additive Manufacturing;
9. Advanced Robotics.
 World Class Manufacturing :-

World Class Manufacturing Pillars:-

1. Safety
2. Cost Deployment
3. Focused improvement
4. Autonomous Maintenance
5. Workplace Organization
6. Professional maintenance
7. Quality Control
8. Logistics
9. Early Equipment Management
10. People Development
11. Energy and Environment
 WORLD CLASS EXCELLENT ORGANIZATIONS
 Characteristics and attitudes of workers
 Management attitudes and policies toward workers
 Competitive focus of management and management policies
 Management accounting and control
WORKER CHARACTERISTICS
MANAGEMENT POLICIES
MANAGEMENT POLICIES
MANAGEMENT ACCOUNTING AND CONTROL
 QUALITY STANDARD AWARDS

 Deming Awards ( Japanese )

 Malcolm Baldrige National Awards (USA)
 QUALITY MANAGEMENT TOOLS

 Check List
 Pareto chart
 The Cause and Effect Diagram
 Histogram
 Scatter Diagram
 Graphs
 BUSINESS EXCELLENCE TOOLS

 Baldrige (MBNQA) – Used in over 25 countries including US and NZ

 European Foundation for Quality Management (EFQM) – Used throughout Europe
 Singapore Quality Award Model – Singapore
 Japan Quality Award Model – Japan
 Canadian Business Excellence Model – Canada
 Australian Business Excellence Framework (ABEF) – Australia
 GLOBALIZATION
• Cost- quality improvement through co-ordinated manufacturing

• Cost- quality improvement through concurrent Engineering

• The order cycle

• After sales customer support

• The design cycle

• Globally coordinated flexible manufacturing

• Globally coordinated R&D

 MANUFACTURING EXCELLENCE

To achieve manufacturing excellence manager has to keep 5 goals

1. Throughput should go up

2. Inventory should come down

3. Operating expenses should come down

4. Yield should go up
 MODELS FOR MANUFACTURING EXCELLENCE
Hallls Framework for value added engineering
 MODELS FOR MANUFACTURING EXCELLENCE

• Schonbergs framework for wcm

• Gunns Model
 MODELS FOR MANUFACTURING EXCELLENCE

• Maskells Model

According to maskell, WCM includes

1. New approach to product quality
2. JIT
3. Change in the way the workforce is managed
4. A flexible approach to customer requirements

People Management Approaches

1. Transfer of responsibility
2. Education and cross training
3. Problem solving and quality circles

As for flexibility following aspects are important

1. Production flexibility
2. Design flexibility

• America’s best plants model

Q&A