Guide to World Class Manufacturing

Regardless of where you are in the production process, producing waste free, efficient, and reasonably priced products should be at the top of your list. World class manufacturing is guided by three main principles:

1. Implementing lean manufacturing and just-in-time principles to reduce production waste and cost. Just-in-time and lean manufacturing principles go hand in hand in making sure that the items produced will meet customer demand rather than be in excess or ahead of need. This can be accomplished by removing any manufacturing process that doesn’t bring value to the customer.

 Examples of wasteful processes include:

• Surplus inventory and lack of product demand
• Correcting expensive defects
• Unneeded transportation
• Overproduction
• Idle equipment or downtime
• Adding useless product features

2. Applying total quality management to decrease the number of defects and improve customer experience. Total quality management is based on the idea that every worker, from management to frontline staff, is dedicated to continuously improving production processes and creating high-quality products.

3. Executing total productive maintenance to help catch operational failures that can lead to defective machinery and equipment. Total productive maintenance (TPM) principle is made up of eight pillars that focus on preventative strategies to improve equipment reliability.

There are several pillars that form the foundation of World Class Manufacturing (WCM). While the specific pillars may vary depending on the organization and industry, the following are some of the most commonly recognized pillars of WCM:

1. Safety: Providing a safe working environment for all employees is a key pillar of WCM. This involves establishing and enforcing safety policies and procedures, as well as providing training and resources to ensure employee safety.
2. Cost Deployment: Cost deployment is a systematic approach to identifying and reducing costs throughout the production process. This involves analyzing and understanding the cost structure of the organization, setting cost reduction targets, and implementing strategies to achieve those targets.
3. Continuous Improvement: WCM is based on the philosophy of continuous improvement, where every aspect of the production process is continuously evaluated and improved. This includes not only processes, but also the tools, equipment, and technology used in the production process.
4. Autonomous Maintenance: Autonomous maintenance involves empowering employees to take ownership of the maintenance of equipment and machinery, which helps to minimize downtime and reduce the cost of maintenance.
5. Professional Maintenance: Maintenance is a critical aspect of WCM, and it involves ensuring that all equipment is operating at optimal levels to minimize downtime and reduce costs.
6. Quality Control: Delivering high-quality products and services is critical to achieving customer satisfaction and maintaining a competitive edge. This pillar involves establishing quality standards, implementing quality control measures, and continuously improving quality through feedback and data analysis.
7. Logistics and Material Flow: Efficient logistics and material flow are critical to achieving high levels of productivity and minimizing waste in the production process.
8. Early Equipment Management: Early Equipment Management (EEM) involves optimizing the performance of equipment from the design phase to reduce downtime and improve efficiency.
9. People Development: Developing skills and empowering employees is a critical pillar of WCM. This involves providing training and development opportunities, promoting a culture of continuous improvement, and empowering employees to identify and solve problems.
10. Environment: WCM recognizes the importance of environmental sustainability and encourages organizations to implement environmentally responsible practices in their production processes.

By focusing on these ten pillars, organizations can achieve high levels of efficiency, quality, and customer satisfaction, while also reducing costs and minimizing waste in the production process.

There are a number of strategies businesses can employ to improve workplace efficiency and production procedures. Examples include:

• Build to order is a production strategy that waits for a customer order to be placed before creating the goods to fill it.
• Reducing assembly line lot sizes helps to reduce inventory, simplify order scheduling, and boost overall product quality.
• Just in time strategies help to eliminate the surplus of goods to focus on developing products that meet customer demand.
• Minimizing item flaws to retain customers and gain a competitive edge in the global marketplace.
• Cross-training workers to ensure everyone is up-to-date on current procedures and knows how to carry out their jobs properly.
• Improving worker engagement to guarantee fewer production errors and minimal waste.

WCM sets the standard for excellence for all manufacturing processes across an organization. You can become a top manufacturer despite the size of your operation or resources.

The following tips on becoming a world class manufacturer can help get you started:

• Develop products as solutions rather than creating ones that don’t serve the needs of the customer.
• Exceed customer satisfaction by handling every client inquiry with care, from the prospect stage to post-sales.
• Execute production procedures that increase item quality and reduce malfunctions on the shop floor.
• Modify manufacturing processes to meet customer expectations and avoid stagnation.
• Emphasize employee training to increase product knowledge, procedures, and productivity.
• Carry out supply chain management tactics that analyze the actual cost of a purchased product from a supplier to lessen unneeded expenses or errors.
• Participate in the product process (design, planning, and development) to ensure production protocols are followed and maintained.

It’s important to carefully study key performance indicators (KPIs) to better gauge if workers are implementing world class manufacturing approaches throughout the factory floor.

Some important metrics to track are:

• Overall equipment effectiveness to evaluate how efficiently operations are followed
• Overall labor effectiveness to measure the performance and quality of your workforce and its productivity
• Scrap rate to assess production quality and output
• First-time right to ensure workers are producing goods correctly to avoid time and money losses
• On-time orders to see how many products were delivered to customers in a timely manner
• Customer complaints to study product fulfillment

World-class manufacturing typically involves the integration of various software tools and technologies to optimize the manufacturing process – Enterprise Resource Planning (ERP), Quality Management Systems (QMS), Computerized Maintenance Management Systems (CMMS), as well as Artificial Intelligence (AI), which can be used to analyze production data and identify patterns, enabling manufacturers to optimize their operations and improve quality. It is critical for these systems to be tied into the work being done on the factory floor, and the activities of frontline teams.

This is where frontline operations platforms come into play.

Connected frontline operations platforms are digital software tools that can help standardize and improve manufacturing operations. They are used to improve communication, training, collaboration, guidance, and support for the workers on the shop floor, and are a critical aspect of world class manufacturing.

Augmentir is the world’s first AI-powered software to standardize and optimize work procedures that help frontline workers excel in their field. Augmentir’s connected worker solution and generative AI assistant can help you eliminate waste and reduce costs by optimizing production processes and minimizing defects and errors.