Becoming a world-class manufacturer? You can achieve this by implementing WCM. How World Class Manufacturing can look in your factory and what continuous improvement techniques are necessary to make the concept succeed, you’ll find out in this blog.
What is World Class Manufacturing?
World Class Manufacturing, abbreviated as WCM, is an approach for production environments that brings together various continuous improvement techniques. These improvement techniques are used to promote efficiency, quality, flexibility, and innovation. In addition to improving processes, WCM emphasizes the involvement and job satisfaction of employees, eliminating waste, and creating a culture of continuous improvement. In this way, a WCM trajectory aims to achieve an organization that performs exceptionally well in both production and operations. All in order to ultimately gain a significant competitive advantage. There are three continuous improvement techniques that form the basis of World Class Manufacturing. These are: TPM, Lean, and Six Sigma. Below, we explain the added value of each technique to WCM.
TPM
Total Productive Maintenance (TPM) is a method that is focused on improving processes in terms of productivity. Small teams, each with their own responsibilities for a specific part of the production process, are continuously engaged in improvement projects to increase process effectiveness. By implementing TPM in the organization, downtime and defects are minimized. Increased productivity, improved quality, and reduced costs are the result. Because TPM fosters a culture of emphasis on preventive maintenance and continuous improvement, it enables organizations to elevate production processes to a higher level. This is extremely important during a WCM trajectory.
Lean
Lean Manufacturing contributes to improving logistical business processes. This improvement technique ensures that only things that add value for the customer are considered important. Lean principles include just-in-time production and continuous improvement. Wastes, including excessive inventory and unnecessary manufacturing errors, are identified and then removed from the process. By reducing costs, saving space, and increasing and stabilizing end quality for the customer, Lean significantly contributes to World Class Manufacturing.
Six Sigma
You only deliver quality when your product meets the wishes and expectations of the customer. The Six Sigma method is fully focused on upholding this quality for the customer. This is done by reducing deviations from quality standards during the production process and stabilizing product quality. The risk of product errors and deviations is thus reduced by identifying the causes of these deviations and taking measures to eliminate these causes in the future.
Achieving ‘World Class’ is done by combining these improvement techniques. The complete production environment is optimized by focusing on productivity (TPM), logistics (Lean), and quality (Six Sigma). With these three different perspectives and techniques, you continuously work toward the same goal: efficiently producing what the customer has in mind. In addition, the three techniques together will lead to standardization, less waste, and a process of continuous and incremental improvement.
What does a WCM trajectory look like?
A WCM trajectory often begins with determining the current performance and goals of the organization. Subsequently, a multidisciplinary team is formed to lead the trajectory. The team conducts a thorough evaluation of current processes, identifies improvement opportunities, and sets priorities. During the trajectory, Lean principles, Total Productive Maintenance (TPM), Six Sigma, and other tools and methods are applied to reduce waste, increase efficiency, and improve quality. At the same time, employee engagement is stimulated through training, increased responsibilities, and fostering a culture of continuous improvement. The WCM trajectory often includes regular evaluations to measure progress and make additional adjustments. Ultimately, a successful WCM trajectory leads to an organization with improved performance at all levels.
Benefits of WCM
World Class Manufacturing will benefit the factory in various ways. Think of better performance, an excellent competitive position, and sustainable growth. We list the greatest benefits of WCM for you.
- Increased productivity: By minimizing downtime, improving workflow, and promoting employee engagement, productivity within the organization increases.
- Better quality: WCM aims to completely prevent defects by implementing continuous improvement and quality control processes. This results in higher product quality.
- Increased customer satisfaction: Enhanced quality and shorter lead times naturally contribute to higher customer satisfaction. And satisfied customers mean that you maintain the quality standards necessary for growth.
- Lower operational costs: By reducing waste, minimizing downtime, and increasing efficiency, the organization can quickly and easily lower operational costs.
- Competitive advantage: If you settle for no less than an organization that operates as a world-class company, you will gain a significant competitive advantage in the market in no time. This advantage can be very useful both nationally and internationally.
- More employee satisfaction: A culture of engagement and empowerment encourages employees to stay and contribute to the success of the organization. A benefit that is very welcome in today’s labor market!
Characteristics of World Class Manufacturers
World Class Manufacturers are manufacturers that stand out from the rest by having quality, flexibility, innovation, and cost-effectiveness perfectly in place within their organization. They pay great attention to process confirmation and create a high level of employee engagement by empowering everyone with their own responsibilities. World Class Manufacturers do not stop at optimizing their own processes but also engage in strategic collaborations with suppliers. This ensures they always have access to the best materials and work to improve the entire supply chain of the organization. Continuous improvement is not a standalone method for them but rather a way of working and leading. Because, only in this way can you reach the top as a world-class manufacturer!
How to implement WCM in your factory?
Implementing WCM in your factory requires a structured approach, with TPM, Six Sigma, and Lean as unique improvement methods carefully applied throughout the organization. Engaged management and motivated employees are needed to create a culture of continuous improvement. Employees and management need to be trained in WCM principles so that problems can be recognized and solved actively. EZ Factory can assist with this by giving all employees access to a central and digital platform: EZ-GO. Here, you can easily place work instructions and checklists that can provide the necessary information both during task execution and audits. EZ-GO helps standardize processes, increase efficiency, and gain insight into performance and quality. Just a few aspects that are incredibly important for implementing WCM in your factory.