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Critical Control
Points
Mass Production World Class
Manufacturing
Logistics �Large batch production
� Just-in-case
inventories
�Specialized, Robust &
Rigid machinery
�Single unit flow production
�Just-in-time inventories
� Flexible machinery and
�rapid machine changeover
Quality � End of line inspection
� Reworking of defects
�Quality-at-source at each
part of production process
Work organisation �Division of labor
between skilled and
unskilled workers
� Specialized R&D and
product development
�Multi-tasking &multi -
skilling
�Continuous improvement in
green areas as well as
specialized staff
Contrasting Mass Production & WCM
5S-Workplace Organization &
Standardization
• Developed in Japan.
• Structured program to
implement workplace
organization &
Standardization.
• Known to improve work
efficiency, safety,
productivity & establishes a
sense of ownership.
• Lays the foundation for
other Methodologies
5s stands for ……
• Seiri Clearing-up
• Seiton Organizing
• Seiso Cleaning
• Seiketsu Standardization
• Shitsuke Self Discipline
Total Productive Maintenance (TPM)
Meaning
• TPM is a maintenance
philosophy designed to
integrate equipment
maintenance into the
manufacturing process
• is a group effort where
the entire organization
works together to
maintain and improve
the equipment.
Goal
• To eliminate losses tied to
equipment maintenance
or, in other words, keep
equipment producing
only good product, as fast
as possible with no
unplanned downtime.
• ‘Can do’ philosophy.
Autonomous Maintenance
• Individual preserving
one’s own equipment
• Significant change from
the theory of “I
Manufacture-You
Repair”
We are too busy
to do regular
checks
They do not
maintain
The machine is
so old, no
wonder it
breaks down
Too loaded to do
corrective
action
They take too
long
Production do not
know to
operate
Maintenance
does not know
its job
Maintenance
(Before)
Production
(Before)
Autonomous Maintenance
Solution
4. Master how to repair the
equipment.
7. All-out autonomous
management
6. Orderliness and tidiness.
3. Learn how to operate the
machine with the required
accuracy and how to
evaluate the product
quality.
5. Autonomous check-up
4. General inspection
2. Study the mechanism and
functions of the
equipments and the
machines.
3. Formulation of clean-up
and lubrication standards
2. Measures against sources
of outbreaks.
1. Familiarize with the
concept of equipment
maintenance and
improvement and with
how to put the idea into
practical realization
1. Initial clean-up
4 steps to become an operator
strong on equipment
Autonomous Maintenance-7
steps
POKAYOKE
Poka Yoke is also termed as “Mistake / Fool proofing”
• Poka “Inadvertent errors”
• Yoke “To avoid”
Classification of POKA YOKE:
• Prediction v/s Detection
• Alarm v/s Shutdown v/s Control
• Contact v/s Fixed value v/s Motion
SINGLE MINUTE EXCHANGE OF DIES
• No set-up should take more
than 9 minutes
• It is a systematic approach
that decreases disturbances
and problem
• Based on team-work and
creativity
• SMED methods is used for
exchange of dies, but also
for cleaning, and for regular
maintenance
SINGLE MINUTE EXCHANGE OF DIES
Problems in setup operations
� Considered to be a skill
� Variability
� No SOP’s available
� Engineering time not studied
� Tool and adequacy of manpower not clear.
Steps in reducing Setup time
� Elimination of the 3M’s
� Reduce external time
� Reduce internal time
� Convert from internal to external time
� Stream line the operations
� Re-look at 1S, 2S, and 3S.
� Standardize procedure
� Training
� Sustain through audits
� Look for next improvement
Just In Time in world Class
Manufacturing
• Uses a systems approach to develop and
operate a manufacturing system
• Organizes the production process so that
parts are available when they are needed
• A method for optimizing processes that
involves continual reduction of waste
Just In Time in world Class
Manufacturing
• Inventory Reduction as
a Tool for Improvement
• Supplier Relationships
• Inventory “Pull”
• Uniform Plant Loading
• Reduced Setup Times
• Shop-Floor Layout and
Production Cells
• Total Quality Assurance
• Preventive
Maintenance
Advantages of Just In Time in world
Class Manufacturing
• Materials Cost Savings
• Manufacturing Cost
Savings
• Sales Cost Savings
Lean Manufacturing
Definition
• A systematic approach
to identifying and
eliminating waste
through continuous
improvement, flowing
the product at the pull
of the customer in
pursuit of perfection.
Principles
• Understanding Customer
value.
• Value Stream Analysis
• Flow.
• Pull.
• Perfection.
Kanban
System
•Kanban is a simple yet effective
control system that can be easily
introduced and adopted in
various production environments.
• It is considered to be the
“central element” of Lean and
World Class Manufacturing.
•Uses a systems approach to
develop and operate a
manufacturing system.
•Organizes the production process
so that parts are available when
they are needed.
•A method for optimizing
processes that involves continual
reduction of waste.
CONWIP stands for Constant
Work-In-Process, and
designates a control
strategy that limits the total
number of parts allowed
into the system at the same
time
CONWIP control. Movement
of parts shown in blue,
circulation of release
authorizations in green.
CONWIP control
Once the parts are released, they
are processed as quickly as
possible until they wind up in the
last buffer as finished goods. One
way to view this is that the system
is enveloped in a single Kanban
cell: Once the consumer removes
a part from the finished goods
inventory, the first machine in the
chain is authorized to load
another part.
How a WCM is achieved
• Develop the awareness of the need to make the
transition to World Class Manufacturing
• Develop the ability to search for relevant tools and
to apply them effectively
• Monitor progress so that an improvement program
can be systematically utilized.
Implementing WCM :
Tools to Measure and Record Progress
Success Factors WCM Tools Measurement Indicators
1. Cost control Just In time logisitics,
quality at source & supply
chain management tools.
• Inventory holdings
• Absence of defects and rework
• Cost of incoming materials
2. Quality Statistical Process Control,
fool-proofing to prevent
errors, Pareto analysis of
types and causes of
production defects
• Customer return rates
• Internal reject, rework & scrap
rates.
• Supplier quality Performance.
3.External
flexibility
Just-in-time logistics,
quality at source and
supply chain management
tools
•· Time from customer order to
• delivery
•· Delivery frequency & reliability
to customers.
• Delivery frequency and
reliability of suppliers
Success
Factors
WCM Tools Measurement Indicators
4. Internal
flexibility
Cellular layouts, single unit
flow, production pulling,
Kanban signaling system,
single-minute exchange of
dies for rapid machine changeover,
supply chain
management
Machine changeover times
Batch and lot sizes
Inventory levels
Throughput time through factory
Machine utilization levels
5. Capacity
to change
(Human
resource
development)
Multi-tasking,
Multi skilling,
Quality circles,
Kaizen groups,
Training,
Incentive schemes.
Numeracy and literacy levels
Labor/management turnover levels
Absenteeism rates
Training expenditure and types of
training
Employee development
Suggestion schemes/continuous
improvement
6.Innovation
capacity
Concurrent engineering,
new product development
techniques
R&D expenditure
Proportion of sales from
new products