World Class Manufacturing Research Articles

The Shen Model for Make-to-Order SME’s

This paper describes a new model developed for make-to-order (MTO) sectors namely SHEN Principles, which aims to fill a gap in the world-class manufacturing (WCM) literature that concentrates on the characteristics of the larger traditional make-to-stock (MTS) sector. Using evidence from the literature, especially the MTO literature and the more comprehensive WCM models, a new model was devised. This was then modified in the light of case study evidence collected from the six MTO companies ranging from small-to medium-sized MTO companies. The model presented in this paper known as “SHEN Principle”, will be the current version of the model after all the modifications have been incorporated.

Evolutions in manufacturing cost deployment

The paper investigates the development of cost deployment and focuses specifically on the new aspects of this methodology as well as on the tangible benefit it brings within a world class manufacturing (WCM) strategy. The research was conducted through a case study involving a plant of a multinational firm and presents findings regarding two specific research questions investigating the differences between current methodology and previous theories and practices and the ability to track cost savings. Our research suggests that cost deployment methodology has evolved from the framework previously developed and it can impact positively on manufacturing firms in terms of overall efficiency and quality. The research has strong practical implications for both managers and entrepreneurs. Future developments of this research are fundamental to test our hypotheses in other organisations

Evolutions in manufacturing cost deployment

The paper investigates the development of cost deployment and focuses specifically on the new aspects of this methodology as well as on the tangible benefit it brings within a world class manufacturing (WCM) strategy. The research was conducted through a case study involving a plant of a multinational firm and presents findings regarding two specific research questions investigating the differences between current methodology and previous theories and practices and the ability to track cost savings. Our research suggests that cost deployment methodology has evolved from the framework previously developed and it can impact positively on manufacturing firms in terms of overall efficiency and quality. The research has strong practical implications for both managers and entrepreneurs. Future developments of this research are fundamental to test our hypotheses in other organisations

Diseño de una metodología para generar un plan de mantenimiento a través de la integración de RCM, WCM y Lean Manufacturing aplicable en procesos de trefilado de alambrón

Se presenta el desarrollo de cinco fases basadas en el Design Thinking (Empatizar, Definir, Idear, Prototipar, Evaluar) con el propósito de diseñar una metodología integrando herramientas de Reliability Centered Maintenance (RCM), World Class Manufacturing (WCM) y Lean Manufacturing, la cual permita generar un plan de mantenimiento aplicable en procesos de trefilado de alambrón particularmente en una empresa mexicana del sector del acero. En las fases “Empatizar, Definir e Idear”, se identifican los problemas principales en procesos del sector del acero de empresas colombianas y una en México, planteando alternativas de solución basadas en las necesidades y realidades, considerando los Key Perfomance Indicators (KPI) esperados. Posteriormente se seleccionan herramientas acordes al problema y a las alternativas de solución planteadas. En las fases “Prototipar y Evaluar”, se integran las herramientas seleccionadas generando un plan de mantenimiento el cual es descrito y representado por un diagrama como evaluación de la metodología diseñada.

Productivity Analysis in AssemblyDepartment Using Objective Matrix (Omax) Method in Labor Intensive Manufacturing

Productivity has become a holistic target in any manufacturing company. Performance evaluation for production areas in manufacturing should be measure by productivity index that already determined in company goals and targets. Currently, the productivity index has been measured by simple calculation, which only considering production result, manpower and working hours. Those calculations still cannot meet management desire about real productivity itself. Management needs productivity also considering some other performance, those are including quality rate, rework rate, manpower, working hour, production result, energy usage, and compliance with the schedule as input. This desire was mentioned in a company mission to be world-class manufacturing. A well-known method as an objective matrix would be used for measuring the productivity index in the company. There would be a different rank of productivity after considering all of the mentioned items when compared with the currently used method. Production could be bigger than other month but on the other hand quality rate and rework, the rate was dropped. Than rank for productivity index in this company would be more complex and could be used as a raw model of productivity measurement internally or externally.

Military-technical cooperation of Russia with the countries of Latin America. Potential for development and risk factors

The article contains the basic principles, trends and problems of military-technical cooperation (MTC) of Russia with the countries of Latin America. By the beginning of the 21st century, Latin America had become a rather promising, large-scale market for the import of military products, attractive to major world-class arms manufacturers, including Russia. This was largely facilitated by the complex of factors prevailing at the regional level, both in geopolitical, national-political, and financial-economic and industrial-technological spheres. As a result, in many countries of the region decisions were taken in the field of military construction aimed at the transition to the modernization of used weapons and military equipment, which are usually represented by outdated models of the 1950-1970s. The article reveals the potentially most significant areas of the Russian military-technical cooperation in the region, the risks and problems that hinder this cooperation, and the favorable prerequisites for building it up in the future.

Identification of World-Class Manufacturing Strategies and Their Implementation Requirements in Food Industry (Case Study: Olive Product)

Identification of World-Class Manufacturing Strategies and Their Implementation Requirements in Food Industry (Case Study: Olive Product)

Does Political Ideology Affect the Growth of Indian Economy? (A Factor of FDI and Make in India as a Structural Transformation)

The Bharatiya Janta Party (BJP) has started its second inning in June 2019, led by Prime Minister of India Shree Narendra Modi. During his first tenure the government has taken so many decisions to accelerate the growth of Indian Economy like launching of Make in India campaign, demonetization and GST Bill nonetheless from the beginning of their ruling the government has adopted the East Asian welfare economic model rather European to pursue social and structural transformation. In September 2014, Modi government launched a flagship project Make in India with an objective to set the Country as an eminent global manufacturing hub, to attract the FDI and world class manufacturer in India by making the business easy for foreign players. It is the perception of many economists that this campaigning has no meaning for Indian economy and it is only slogan and propaganda of this party. In this research paper we tried to check the effect of this maneuver on various economic barometers like FDI, GDP, Trade openness and foreign exchange etc and we also tried to give some recommendations to the government on the basis of the findings so that the campaign may be continued with full of energy and improvement. This is well acknowledged under the supervision of Prime Minister Shree Narendra Modi , the Foreign direct investment to India has grown up by 6% to 42 Billion USD with a brawny inflows in different sectors like communication, manufacturing and banking services , as per the report of United Nation India is top ranked country among the top twenty host economies of the world.

An integrated AHP-GTA approach for measuring effectiveness of quality tools and techniques

Modern organizations that wish to be successful and to achieve world-class manufacturing must possess both effective and efficient use of Quality tools and techniques (QT&T) for enhancing their performance. A large number of tools, techniques and systematic methodologies are being used in industries for enhancing their performance. Different tools and techniques have different perceived effect on quality improvement. Implementation of QT&T in different manufacturing organizations is not an easy task and requires a methodology to evaluate the effectiveness and intensity of individual QT&T. In the present exertion, various QT&T are grouped into six different categories namely, new product development tools (NPDT), decision making tools, data collection and analysis tools, lean tools, performance measurement tools and software tools which have been analyzed by using integrated multi-criteria decision making approach based on graph theoretic approach and analytic hierarchy process to measure the effectiveness of QT&T. This paper addresses NPDT tools are having high effectiveness and impact on manufacturing organization as obtained in the analysis.

Previous Studies and Differences Between Lean Management and World Class Manufacturing

The main objective of this study is to determine the relationship between Lean Management (LM) and World Class Manufacturing (WCM) practices of aeronautical company in Italy. The methodology should help managers to select those principles and tools of Lean Manufacturing and WCM that are expected to be effective in their company. The research aims to integrate the two models and to achieve a global manufacturing performance in order to maximize the company performance. To this end, a methodological approach, based on Fuzzy Cognitive Maps (FCMs) and the Analytic Hierarchy Process (AHP), is proposed to quantitatively evaluate relationships between LM and WCM. The proposed model allows to identify key factors of Lean and WCM practices and to measure the quantitative relationship between these strategies. The final output is a dynamic analysis designed to identify how relations change with each individual factor.

A systematic review of the integration of best practices for world class manufacturing

Manufacturing organisations are trying to become world class by integrating best practices. While multiple authors have studied world class manufacturing (WCM), no paper consolidates these results. Further certain inconsistencies are found in existing WCM frameworks. A need was therefore felt to clearly identify and define the scope of best manufacturing practices identified from different countries and industries. 173 research papers on WCM were collected from different online databases and reviewed for the purpose of this study. A descriptive analysis was performed to understand the timeline, geographic, author and journal related trends of the papers. Papers were also classified based on content and industry settings. The best practices identified were defined and the popularity of each best practice was evaluated on the basis of number of mentions. The paper finally proposes a new framework for WCM, inspired from the functioning of the human body.

“Optimization of Plant Layout in Manufacturing Industry”

The world’s globalization and consolidation result in increased competition for manufacturing industry. A factory must always attempt to achieve world class manufacturing and quality to survive long in the growing market. Therefore it is important for a MSME sector (Manufacturing Industry) to develop their way of working continuously as per World Class Standards. In this research work, current layout of a manufacturing MSME industry is studied and a new layout is developed based on the systematic layout planning to reduce the meter movement, searching time and increase productivity. The company has presently working on processes layout. The number of equipment/machineries available and meter movement have been analyzed. The detailed study of the plant layout such as operation process chart, activity relationship chart and the relationship between equipment and area has been investigated. The new plant layout has been designed and compared with existing plant layout with the help of Spaghetti Diagram. The new plant layout shows that distance and overall cost of material flow from stores to dispatch area are significantly decreased. The implementation of proposed model will help in the overall improvement of production performance of manufacturing industry. This research work also helps to other small industries having such type process layout in increasing their productivity and achieving 100 % efficiency.

WORLD CLASS MANUFACTURING (WCM) MODEL AND OPERATIONAL PERFORMANCE INDICATORS: COMPARISON BETWEEN WCM FIRMS

World Class Manufacturing is an application system that combines best practices which are compatible with each other so that businesses can continue their activities systematically. WCM model has ten operational pillars. In this study, the operational pillars of the WCM model and the performance indicators in which the applications of these pillars are followed are elaborated. The study was designed to monitor operational performance in the WCM model with the help of KPI/KAI’s and investigate the effects of operational pillars and performance indicators on total WCM performance. In the research part of the study, two different WCM operator firms are compared and their KPIs are shared.

Impacto del diseño para cambios rápidos (DFC) en la manufactura moderna

El avance de las tecnologías en la industria de la manufactura, así como la necesidad de contar con procesos más rápidos y eficientes que brinden un mejor desempeño en la calidad, mejores tiempos de respuesta, flexibilidad y rentabilidad, es un tema importante en la manufactura de clase mundial. Estos indicadores son claves para que una empresa pueda mantenerse en la competitividad de los mercados, que exige una alta diversidad en productos y de volúmenes de producción. En este sentido, uno de los factores claves que contribuye a que un proceso sea más rápido y eficiente, son los tiempos de preparación o de cambio que se dan entre un producto y otro en el proceso de fabricación; aunque existen herramientas de Lean Manufacturing enfocadas a acortar estos tiempos, se ha demostrado que, con el uso de la metodología “Design for Changeover” (DFC), la cual considera estos cambios desde el diseño del equipo, se pueden abatir en gran medida los tiempos de cambio e impactar de manera positiva la flexibilidad y fabricación de lotes pequeños. En este trabajo, se analiza la literatura existente del DFC y el impacto que ha tenido, así como los factores que han intervenido, al fin de aportar un marco de referencia a las industrias interesadas en acortar los tiempos de cambio en sus procesos productivos.

The evolution of world class manufacturing toward Industry 4.0: A case study in the automotive industry

In order to increase the level of global competitiveness and improve the performance of production system, a large number of manufacturing companies have implemented world class manufacturing (WCM) approach, which has developed based on the third industrial revolution and the need for mass production. The evolution in production equipment and communication technologies, and the demand of markets for personalized mass production, have forced manufacturing companies to transform their production systems and prepare for a revolution. This revolution, known as Industry 4.0 (I4.0), or the digital transformation, has been introduced as a new type of organization of manufacturing systems that is more flexible and agile, and is based on using large amounts of information and data in the decision-making process. One of the main characteristics of this concept is decentralization, which allows different subsystems to make decisions autonomously in order to have self-organization systems. There are some important differences between the principles of WCM and I4.0. World class manufacturing is mainly based on continuous improvement and cost reduction, without a global vision for profit optimization. Industry 4.0 is mainly based on using all accessible information and data of systems and making decentralized decisions, but it also involves a global vision and a systemic approach to global profit optimization. However, achieving these objectives takes a very long time, and the challenges are numerous. As with all projects, for a transformation project to succeed, it is very important to define the transition phase and the way to change and introduce these new principles. This paper presents part of our research project, in collaboration with the Fiat Powertrain Technologies company, concerning the transformation of their production system toward the factory of the future. We highlight the design principles of I4.0 and the potential of the WCM system for transformation and achieving development of the characteristics of I4.0. We focus on five of the principal technical pillars of WCM and the steps in their development, and present some modifications in adoption of the design principles of I4.0. An example of change in the professional maintenance pillar of WCM is also presented.

Emergence of ISO 9001:2015 standard and its linkage with world class manufacturing strategies

Right from the days of their release, ISO 9000 series standards-based quality management system (QMS) has been implemented in large number of organisations. Whenever revisions were made, organisations tuned their QMS to adhere to the respective revised version of ISO 9000 series standards. This kind of need has arisen now due to the release of ISO 9001:2015 standard. In the context of observing this need, the survey reported in this paper was carried out with the objective of exploring the nuances of ISO 9001:2015 standard and its implementation trend in organisations. The results of this survey have indicated that the organisations are now slowly turning their QMS to adhere to the stipulations of ISO 9001:2015 standard. Further, in this article, the need of integrating 'total productive maintenance' (TPM) with the ISO 9001:2015 standard-based QMS is pointed out. This article is concluded by claiming that such integration and its implementation will enable the modern organisations to attain world class manufacturing goals.

The Conceptual Design of Flexible Manufacturing System with the Use of Computer Simulation in Enterprise Dynamics

Nowadays, production processes become more and more complicated because of global market competition and the need for flexible changes in production in order to meet customer needs. That is related to the frequent reorganization of production systems and require adequate operations management, internal and external logistics, and project management from the stage of conceptual design to the industrial implementation. Currently, we may observe an increased use of automation and robotization, which replace human labor. Modern industrial robots can work similarly to a human operator, but the replacement of a human operator with a robot is related to some technical problems and excessive cost, therefore robotic workstations must be properly designed. The aim of the study is developing a method which allows estimation of productivity growth associated with the replacement of human labor with industrial robots at an early design stage. The production flow in the manufacturing system and internal logistic processes were modeled in the Enterprise Dynamics software, which enables simulation and visualization of discrete production processes. The models were built taking into account availability, performance and quality parameters, which enable a direct calculation of OEE (Overall Equipment Effectiveness) indicator, which is one of most important Key Performance Indicator (KPI) used in World Class Manufacturing (WCM) methodology, especially in automotive industry. The use of OEE indicator enables comparison with similar manufacturing systems. The example of the conceptual design of the flexible manufacturing cell, with CNC machine tools, which can be operated by humans or robots, is presented. The production process includes two machining operations of large and heavy parts, which are difficult to handle, therefore robots are preferred to apply. The computer simulation of the sophisticated model of the flexible manufacturing system with machines, operators and robots with reliability parameters allows better representation and understanding of a real production process at the stage of conceptual design. The experiment results confirm the advantage of the application of robotic operated production systems comparing to manually operated machines with production growth of about 17%. However, robotization is related to very high investment cost, therefore detailed economic analysis is required, including a comparison of labor cost and robot cost. Obtained results can be used for detailed designing of manufacturing systems and robotic workstations.

A REVIEW ON WORLD CLASS MANUFACTURING (WCM)

A REVIEW ON WORLD CLASS MANUFACTURING (WCM)

Lean Production and World Class Manufacturing: A Comparative Study of the Two Most Important Production Strategies of Recent Times

Lean Production and World Class Manufacturing: A Comparative Study of the Two Most Important Production Strategies of Recent Times

Lean Production and World Class Manufacturing: A Comparative Study of the Two Most Important Production Strategies of Recent Times

Lean Production and World Class Manufacturing: A Comparative Study of the Two Most Important Production Strategies of Recent Times