Seven key elements for successful world class manufacturing implementation

¶ … Manufacturing

Seven Key Elements for Successful Implementation

Norman Binette, Jr.

Biddeford, Maine

Manufacturing organizations are built on the premise that they possess the ability to provide a wide variety of quality products for their customers. This reputation is dependent upon the constant review of existing processes and the identification of new and innovative methods of production that will enhance and increase the diversification of product lines. One such process that has proven itself as a valuable commodity in recent decades is World Class Manufacturing. This process involves a number of complex steps encompassing a variety of business units that are subject to continuous review and improvement. This process is designed to maximize employee productivity at all levels of the organization, from the assembly line to executive management. A successful World Class Manufacturing strategy will provide the organization with numerous opportunities for growth and will enable a successful transition to unique and innovative production methods.

THE PROBLEM

Businesses face constant pressure from their customers to reduce pricing as a result of highly competitive market conditions in a globally aggressive environment. Failure to repeatedly reduce costs could ultimately lead to the loss of future profitability and the demise of the firm. It is often puzzling for firms of all sizes to identify ways to reduce costs on a continuous basis to simultaneously sustain productivity and improve profitability. As a result, many organizations are left behind since they do not possess the appropriate resources and knowledge to successfully promote their business strengths. Subsequently, the failure to implement a strategy for business growth with intensity and clarity will lead to a premature demise. Businesses must take a proactive approach in the development of innovative strategies, but the means by which such lofty objectives are achieved are often bewildering and are limited by available resources, particularly in manufacturing environments.

FINDINGS

Seven key elements have been identified as essential components that are required to implement a World Class Manufacturing Strategy. These include leadership, empowerment, product cell layout, material requirements planning, just in time, total quality management, and standardization. These must be implemented in the order listed to initiate a successful transition. This process was developed and refined over a five to seven-year period by a Management team at Pratt & Whitney and was initially led by Edward W. Northern. A visual presentation will be included as an appendix that provides a detailed overview of the World Class Manufacturing process as it has been successfully implemented in a number of organizations across the world.

ABSTRACT

CHAPTER 1: INTRODUCTION

The Problem

Purpose of the Study

Importance of the Study

Scope of the Study

Rationale of the Study

Definition of Terms

Overview of the Study

CHAPTER 2: REVIEW OF RELATED LITERATURE

Introduction

Origin and description of World Class Manufacturing

Leadership

Empowerment

Product Cells

Product Flow - Just in Time

Material Management

Total Quality Management

Summary

CHAPTER 3: METHODOLOGY

Approach

Data Gathering Method

Database of Study

Validity of Data

Originality & Limitations of Data

Summary