Amirul Bin Abd Rashid

Faculty of Mechanical Engineering,

University Teknologi MARA.

Defination of WC
Characteristics of WC Company
Key for Continous Improvement
Lessons for Asian Management
Companys that have reached World Class
Lessons from Japanese Style Management

World Class Manufacturing Is

A position of international manufacturing excellence,

achieved by developing a culture based on factors such as
continuous improvement, problem prevention, zero defect
tolerance, customer-driven just-in-time production, and total
quality management

The capability of a manufacturer to compete with any other

manufacturing organization in a chosen market, with the
aspiration of achieving world-beating standards in all
organizational aspects. World class manufacturing
encompasses the practices of total quality management,
continuous improvement, international benchmarking, and
flexible working.
Definition sourced from Bnet Business Director

World Class Manufacturing is a different set of concepts, principles,

policies and technique s for managing and operating a manufacturing
company.

It is driven by the results achieved by the Japanese manufacturing

resurgence following World War II, and adapts many of the ideas
used by the Japanese to gain a competitive edge.

It primarily focuses on continual improvement in :

Quality
Cost
Lead Time
Flexibility
Customer Service
Innovation

 Lead

Time Reduction
Speed time-to-market
Cut Operations cost
Exceed customer expectations
Manage the global enterprise
Streamline outsourcing processes
Improve business performance visibility

Implementations usually involve the following

philosophies and techniques:

Make-to-order
Streamlined flow
Small lot sizes
Families of parts
Doing it right the first
time
Cellular manufacturing
Total preventive
maintenance
Quick changeover

Zero Defects
Just-in-time
Variability reduction
High employee
involvement
Cross functional teams
Multi-skilled employees
Visual signaling
Statistical process
control

It is a means to achieve :
High quality
Low costs
Delivery on time
Increasing market share
Higher profitability
Achieving customer delight
Long term viability

A successful continual improvements activities

consist of the following tasks:
Clear

mission, vision, values and objectives at the

management level and disseminated throughout the
organisation.

Effective

communication

Well

planned and organized system

implementations.

Equal

opportunities for all the employees.

Vertical

progression Vs horizontal moves perception.

Teamwork

workers.

& empowerment of the shop floor

Policies world class companies pursue to achieve the

necessary contribution from employees :
Learning process and the content of training; through
experience and self discovery.
Mentoring and coaching; Train the trainers e.g. Managers
Training and development as an investment.
Inculcate a lifelong learning culture.
Team building and team training activities with the
participation from senior and top management.
Participation at all level in the relevant training and
development.
An integrated approach for training and development
plans that give training needs for the individual from
appraisal, but that clearly link to the organisations
mission, vision, values and objectives.

12,000 companies were surveyed according to the

Malcolm Baldridge National Quality Award criteria. Out of
1,039 in total, the breakdown were as follows:
Country

World Class Recognition

Japanese

675

North American

221

West German

71

British

40

French.

32

The Malcolm Baldrige National Quality Award was created by Public Law 100-107,
signed into law on August 20, 1987. The Award Program, responsive to the purposes of
Public Law 100-107, led to the creation of a new public-private partnership. Principal
support for the program comes from the Foundation for the Malcolm Baldrige National
Quality Award, established in 1988.

 Think Quality. Strive constantly to improve your product;

Inspired to seek ways to do everything better at all level; and cut
the product rejection rate.

Be Competitive. Match or exceed every improvement made by

the competitors; Competitive pricing; Ready and prepared to give
100 per cent service; Think creative to promote your products
with the objective to outperform competitors.

Treasure your employees. Treat workers fairly; Give all

employees equal consideration; Provide lifetime employment, or
at least, fire no one before exhausting every other possibility;
Share in the companys good times with regular bonuses. In other
word, treat all employees like the conscientious, loyal, intelligent,
and hardworking people you want them to be. And thas what
they will surely be.