World Class Manufacturing (WCM) - How to Implement WCM

Diego Marinho, a university professor with expertise in technology management and production engineering, explains the transformative power of WCM.

Understanding WCM:

• WCM emerged in 2006 through collaboration between European and Japanese experts, built upon ten technical and managerial pillars, aiming to instill a culture of operational excellence.
• It addresses the challenge of sustaining methodologies within companies even after the departure of key personnel by providing a robust implementation framework.

Key Principles of WCM:

• WCM emphasizes a culture of continuous improvement, wherein all employees contribute to achieving world-class production standards.
• The methodology stresses visible and transparent systems to track progress and ensure accountability throughout the organization.
• It promotes the use of standardized processes and tools, with leadership playing a crucial role in driving efficiency and reducing losses.

Direction and Implementation of WCM:

• WCM is guided by matrices prioritizing safety, quality, and productivity in all projects and initiatives.
• Implementation involves establishing safety models, identifying and addressing production losses, and prioritizing improvement efforts based on data analysis.
• The methodology's success hinges on strong leadership support, regular audits, and employee engagement across all levels of the organization.

Assessment and Evolution of WCM:

• Audits, conducted every six to twelve months, evaluate progress and adherence to WCM principles, ensuring continuous improvement.
• Auditors focus on identifying areas for enhancement, encouraging proactive measures to address inefficiencies and sustain momentum.
• WCM's evolution is marked by incremental improvements, reflected in scores across technical and managerial pillars, indicating organizational growth and maturity.

Application and Benefits of WCM:

• WCM application involves aligning objectives with organizational goals, leveraging employee expertise, and fostering a culture of innovation and collaboration.
• The methodology yields tangible benefits such as waste reduction, improved productivity, and enhanced product quality.
• It enables organizations of all sizes and industries to implement systematic approaches to identify and address operational inefficiencies. 

https://www.youtube.com/watch?v=KBDARhVyEH0&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=194

We'll know understand WCM's technical and managerial pillars.

Technical Pillars:

• There are 13 technical pillars, represented as 10 due to some being paired.
• Each technical pillar contributes to a total score of 100 points.
• Technical pillars encompass areas like maintenance, quality control, and logistics.

People Development:

• Personnel development is crucial for sustainable improvement.
• Training focuses on competencies and job-specific skills.
• Mapping competencies helps in understanding workforce capabilities.

Energy Management:

• Energy management aims to identify and reduce energy wastage.
• Sustainable energy practices are emphasized for environmental preservation.

Focused Improvement:

• The WCM framework promotes ongoing improvement efforts.
• Measurement and analysis are fundamental for identifying areas of improvement.
• Projects focus on sustainable energy practices and operational efficiency.

Managerial Pillars:

• The sequence of addressing essential pillars is not fixed but guided by cost deployment.
• Managerial pillars include management commitment, organizational efficiency, and worker motivation. 

https://www.youtube.com/watch?v=uSkBK7Vt1NE&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=196

WCM implemented step by step within the factory

Matrices and Pillars of WCM:

• WCM implementation involves three matrices: safety, quality, and productivity.
• Each matrix focuses on the biggest losses within the factory.
• Cost deployment quantifies losses and identifies areas for improvement.

Structured Implementation:

• Organized process of tackling problems.
• Rigor in application is essential for success.
• WCM is not temporary; it's a continuous path towards excellence.

Development and Resources:

• Importance of developing skilled leaders.
• Hiring specialized consultants for successful implementation.
• WCM requires commitment and continuous improvement.
• Need for focused and organized strategies.
• Implementation requires deep knowledge and consistent application.

Training and Education in WCM:

• Importance of spreading WCM training.
• Training available for various audiences.
• Encouragement for the formation of WCM specialists.

Results of WCM:

• Pursuit of operational excellence and efficiency.
• Reduction of losses and increased productivity.
• Transformation of organizational culture towards continuous improvement.

Feedback and Evaluation:

• External feedback is crucial for progress.
• Regular audits help maintain focus and quality.
• Critical view is necessary to identify areas of opportunity.

Sustaining WCM:

• Maintenance of commitment to WCM principles.
• Constant updating of practices and methods.
• Culture of learning and continuous adaptation.

Course Forward:

TBD

https://www.youtube.com/watch?v=mEtVIlOo6RE&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=197