WORLD CLASS MANUFACTURING NOTES Dr. Abe Feinberg

Reference: Schonberger, Richard J., World Class Manufacturing,

Free Press Division of MacMillan, New York 1986, pp. 1100.

The motto: CONTINUAL, RAPID IMPROVEMENT

Major concepts: Just in Time (JIT),

Total Quality Management (TQM),

Total Preventive Maintenance (TPM),

Cellular Technology or Group Manufacturing,

Reduce Deviations from Zero Defects,

Reduce Deviations from Zero Lead Time,

Variability Reduction (of everything),

Increased Operator Responsibility,

Increased Operator Leadership,

Group Rather than Individual Incentive Pay!,

Employee Involvement,

Kanban.

The results: Simplicity,

Better Maintenance with Fewer People in the Maintenance Department,

Better Quality with Fewer People in the Quality Department,

Better Accounting with Fewer Accountants,

Better Production Control with Fewer Production Controllers,

Better Materials Management with Fewer Materials Staff,

Better Information with Less Data Processing,

Better Output with Less Floor Space.

MANAGING TO ADD VALUE NOT COSTS

Do the following activities add value or cost?

Counting items, moving items, storing items, expediting items,

searching for items, inspecting items,

taking items out of one container and putting them in another,

accumulating items to make larger quantities?

OVERSTATED ROLE OF CAPITAL

Many efficiencies can be introduced into the

production process without significant capital

costs (e.g., minimize movement),

upgrade the capabilities of existing equipment more often

than buying new equipment, add capacity in small

increments as sales grow, FLEXIBILITY is critical

NO TOLERANCE FOR DOWN TIME IN JIT SYSTEMS

Use operatorcentered preventive maintenance.

Make time for maintenance.

Deming’s 14 Steps to Quality

(See p. 271 of Gaither & Frazier’s Text, 9th Edition, for slightly different wording.)

  1. Drive out fear.
  2. Eliminate quotas and numerical goals.
  3. Break down all barriers between departments.
  4. Eliminate inspection. Learn to build products or render services right the first time.
  5. Institute a vigorous program of education and self-improvement.
  6. Remove barriers that rob workers of their right to pride of workmanship.
  7. Institute leadership. The aim of leadership should be to help people do a better job.
  8. Eliminate slogans, exhortations and production targets.
  9. Adopt a new philosophy. This is a new economic age. Western managers must awaken to the challenge, and learn their responsibilities and take on leadership for change.
  10. End the practice of awarding business based on the price tag. Move toward a single supplier for any one item. Base this long-term relationship on loyalty and trust.
  11. Improve constantly and forever the system of production and service.
  12. Put everybody to work to accomplish the transformation.
  13. Institute job training.
  14. Create constancy of purpose toward improvement of product and service to become competitive and to stay in business and to provide jobs.