World Class Operations

Ans.1] I am the Maintenance Manager of a Pump manufacturer and have launched their TPM
Program .
1] a.] So the concept of 5S and 5S is the foundation of TPM by the following : 5S is a Japanese
technique for assembling and amplifying work space . The 5S concept is a technique for
improvement in productivity and efficiency of the work space . If we comply with the 5S
execution in the pump manufacturing process then we can enhance the productivity , employee
staff and commitment . By grasping the 5S we can also do better work flow and lessen wasted
time with energy. The 5S stands for S : Sriri - sort , Seiton - set in order , Seiso - shine , Seiketsu -
standardise and Shitsuke - sustain .

1. Sort : The first S in this technique is important to execute waste and do optimization in the
work environment . By implementing the first S is critical for the achievement of the
pump manufacturing process as the 5S are twisted and only work if the earlier processes
are executed rightly . As starting the first S precisely hold on overall tools that I will utilize
daily and reserve apart anything that I am not utilising a daily need . To make sure I
execute this first S correctly as I require to catalogue the tools in my work space and then
place the frequency with which it is utilized . The better route to do this is by overloading
the staff utilizing the work environment to perform this . As them I know what items are
important for the daily operating of the work environment and which not a bit , then I will
proceed to the other process which is the red tagging . Here in this situation , I would write
a red sticker full with important information regarding the item I would not utilize to use
routinely . The I would reserve it far till I would require to utilize again .

2. Set in order : Once the working items have been categorised then its need to fix the actual
environment in order . This will make sure that my work environment is utilizing the
space effectively in a manner that increases the safety and productivity . As to start this , I
will require to explain what is the majority analytical design for my work environment to
complete routine procedures neatly . When selecting the environment that I need to set in
order then I require to make sure that there is no problem as to where is stored and if
anything would be not in place then I’ll be informed . To perform this consider regarding
the tasks , sequence and frequency . This will support me to plan the design in the major
anytical road to built an effective organised work environment for making a environment
where staff can move shift all over around safely and in which is a neatly determined
frequency of utilizing the inventory and tools must be colour coded to make visual control
effortless . The four principles of movement economy : Eliminating the number of moves
, Simultaneity of movements , Eliminating the travel distance , making the movements
smoother and more manageable for success of this process .

3. Shine : As I have categorised the equipment and fix the environment in order , so now it
should be made shine . The aim of the this S is having a clean working space . To whirl
this to follow determining the source of grubby , developing cleaning standards and
reducing or eliminating the source of dirt . This process not ends to include cleaning
but also well organized maintenance work to eliminate conditions that would arise dirt and
tragedy like leakages . For increase in the execution of this S : Utilising hoods and casings
to keep away from projections , Vacuum clearing is good than blowing when it arrives to
maintaining the work space neat , designing a logical circulation of liquids and parts by
 various channels , Benchmarking the items that are more presumably to develop a source
of dirt like barrels and ensuring cleaning points are visible to all .

4. Standardise : As I have categorised my equipment then set the work environment in

sequence which has made it shine then its it comes standardisation of the process .The
motive of the above 3S is to develop the condition of recommendation that I’ll require to
arrive at the first stage of efficiency in words like selection , ordering and cleanliness .
Standardisation is important for making sure the standards Which I have set are being
imposed and that before customs are not aren’t crawling back . The operations would be
standardise by the following : approving the state of reference in the work environment
utilizing visual guides such photographs , sketches . This support notice instantly if the
standards drop down , determining neatly the tasks the workers staff are incharge of ,
creating or modifying operating methods for various steps , bringing together response rule
, making assure of rules and regulations which are transparently visible in the work
environment , determining how to select and interact inconsistently . When the space is
standardised , an external person to the work place must do testing it by arriving in and
making assure they recognise the work place of the space fast and what action occurs in
which operating lines slightly by viewing at the instructions . If the external person
manages to perform this then the standardisation process will be achieved .

5. Sustain : To create assure the 5S technique workout , I will require to make sure that
carrying out the last 5S to sustain the system that has built . The system is kept constantly
in space occurring the reoccurrence and the agile participation of all in my work
environment . With the repetition of these processes , the major for standards will placed
constantly improved by the PDCA cycle : Plan : defining aim and boundaries to apply the
5S , Do : teaching , training , apply the standards and identification of agile , Check :
checking the standards are strong and find out how the 5S techniques are working , Act :
Analysing and taking out mistake if any agiles .
• 5S plays a crucial role in the TPM . By implementing 5S the organizations can develop a
neat , safe and a well organized work space that helps TPM aims like improvement in
equipment reliability , decrease in down time and generating product quality along with it
do continuous improvement with employee commitment which is important for the TPM
achievement .
• Thus , by implementing the 5S techniques on regular basis I can be e able to navigate new
opportunities for improvement , which will come out in increase productivity ,
profitability , and safety in the pump manufacturing .

2] Some of the benefits that I expect from this TPM initiative are below :

• Low Unplanned Maintenance and Equipment Down Time : Taking care of my

equipment all neatly well planned and scheduled maintenance makes sure my tools are
usually very well maintained . Executing the driven tasks that outcomes in minor
equipment loss , reducing downtime . By supporting I will look over the lost time spent
and delays , TPM upgrades overall equipment effectiveness which leads to increase
performance and profits .

• Lower Manufacturing Costs : Increasing overall equipment effectiveness makes pump

manufacturers to reduce production costs which consists expenses like to equipment
stoppage time and unplanned repairing . Specially together with enhancement to quality ,
 performance , a decrease in breakdown and maintenance costs supports to lead way to
overall higher profit .

• Increase in Work Environment Safety : Imposing the TPM’s 5S technique permits for a
carefully organized and neat work environment . This supports with unknown issues and
dares to continue a smooth work space , which in turnout leading to some accidents and
safety risks .

• Enhancing Employee Satisfaction : TPM entitle all plant staff to take ownership and develop
confidence in their equipments . By doing maintenance a personal investment in the work
environment , major equipment durability and good performance from the team . TPM’s
complete proceeds to manufacturing motivates innovation by the dividing collaborative
knowledge .

• Extreme Quality and Some Defects : TPM gives to the quality and constantly of the
production line by increasing performance . Along other extreme quality of product and
greater speed of delivery and have some production correction to less .

Thus , these are some of the benefits which I expect from this TPM initiative within our
manufacturing zone .

Ans.2] Global Manufacturing firms in diverse sectors such as Automotive (Toyota, Daimler),
Electronics (Apple, Phillips), Appliances (Kohler, Black & Decker), etc., are highly reputed for
their unflinching commitment to Quality. As quality is of supreme importance and the basic need
from the customer, thus the global manufacturing firms must take necessary steps to implement
quality and achieve their goals . So the key factors that are part of Quality are the following :

• Source Quality Components : Issues would arose depending on what type of product which
is selected for every component as they would attached nicely or not . It is an important on a
new product customers checklist - is the product durable ? How much duration will the
various components and accessories last in the product as time goes on ? The quality and
workmanship of the products motivate how the product will fare over time . Thus, the
durability of selected materials and the manufacturing process should be calculated on
regular basis . So there should be a continuous and reliable supply of excellent quality parts .

• Make Standardized Checklists : To make excellent quality products , it is suggested to make

standardized checklists for each step of the process so that quality can be guaranteed till the
production . This checklist must contain both internal and external validation steps which are
utilized to confirm that all tasks has been finished adequately .

• Listing the Standards : Standards can change for various types of products and different beliefs .
In such condition , the quality standards consist of different levels .

• Certify Consistent Processes : Product manufacturing is a process that takes place over a
duration depending on the product . The aim to promising quality is consistency , which means
that each step of manufacturing process should be completed with the same attention and care .
 This will make sure that the products will fulfil the standards and no issues now and then .
Moreover the employees must to be well trained so there will be lower setbacks . With the
experience comes competence and this will way to excellent quality products .

• Wearing and tearing : Wear and tear is a typical part of the life cycle for all the
products . It using what happens with regular usage . This can consist of paint peeling
, noises from different parts of the product , destroyed rubber seals quality and ruined
wiring , etc. Taking list of these issues and search where or how they develop . Then
know them and make improvement changes .

• Arranging Routinely Testing and Troubleshooting : It is necessary to arrange

regular routine testing and troubleshooting of the product . Testing will search any
errors before they can become big issues and troubleshooting will support fix those
problems when they do come . Also can conduct quality controls by any 3rd party
inspection organization to examine the product . This will make sure that we are
manufacturing a excellent quality of product . As it makes sure that we are following
all industry regulations .

• Efficiency Measurement : The goal for the manufacturing firm businesses must be to
increase energy efficiency so that there is less energy wastage making efficiency rates
better slightly than worsen with each manufacturing cycle .

• Exclusive Product Characteristics : Quality also have to do with complete in the

self propelled bet . Customer see for excellence characteristics that make their
experience good . Possessing such characteristics accessible develop from part of
giving quality products .

• Keeping Updates of Changes which Effect Quality : Keeping up with changes that
would effect product quality is important in manufacturing . If there are new quality
standards or regulations launched they are needed to be addressed . Any extreme
updates can effect the manufacturing firms .

• Sustainable and Environment Control : Sustainability and Carbon impressions are

becoming extensively essential in the manufacturing firms . The products which are
manufactured should obey by on going regulations and goal to reduce the green house
gas emissions .

• Keeping straps on vendors : A sharp path for surety that getting the excellent
materials is by keeping in contact with the vendors . Firstly let them offer their jobs
for approval before ending up and if any problem arise then get in touch with them
and define them .

• Function with licensed Manufacturers : Whenever plan on navigating a

manufacturing partner , then do not look on the best rate , look out to examine out
their licenses along with certifications them as evidence as having high standards and
finer care for description .

Thus there are many factors that give to major standards and excellent quality which commit
all the value chain from vendor over way to the market .
Ans.3.a] Quality Awards act as motivation for the companies to carry on with world class
standards in manufacturing . Discussing the difference between National and International
Awards :

• National Quality Awards include Rajiv Gandhi National Quality Award and
Golden Peacock National Quality Award where as International Quality Awards
include Malcolm Baldridge Quality award , Deming Prize , Japan Quality Model
and European Quality Award .
• Rajiv Gandhi National Quality Award was started at 1991 whereas Malcolm
Baldridge Quality award was presented at 1987 and the European Quality Award
in 1991 .
• National Quality Award was presented for Quality Improvements in Indian
manufacturing companies whereas The International Quality Awards were
presented for as a measurement of path of success and it was recognised by
companies who were at excellent level .
• National Quality Award provides increase in customer service and facing
competitive regardless quality standards over the globe where as the International
Quality Awards supplies Recognition and Road to improved quality .
• Rajiv Gandhi National Quality Award was the first award for the companies to
carry on with world class in manufacturing where as the Deming Prize was the
first major award .
• National Quality Award encouraged manufacturing companies and services for
excellence where as the International Quality Awards encouraged to be
outstanding to become the benchmark of quality for the companies to carry on
with world class standards in manufacturing .
• National Quality Awards are based on several criteria for International Quality
Awards whereas the International Quality Awards are based on the foreign quality
models .

Thus the National and International Quality Awards act as a inspiration to the companies
to carry on with world class standards in manufacturing .

Ans.3.b] With reference to Quality Awards the Deming Criteria for Performance Excellence
in assessing the award are the following :

• Scheme : Techniques of developing valid and continuous approach , utilization of

statistical techniques , Scattering of policies , analysis of outcome , commitment
between schemes and strategy which depends on terms .
 • Company : The scope of leadership and authority , Participation in linking
departments of the company , Actions of representatives , use of workforce and
productivity and excellence circle tasks and identification of quality assessment .
• Spreading of Information : Development programs for employees , Introducing
importance of quality & control , upskilling statistical techniques and performing
tasks of quality circle .
• Assembling , distribution and utilization of information data on Quality : A
process of assembling and supplying administrative units with data on quality , the
rate of information data distribution , data approach , statistical differentiation and use
of outcomes .

• Assessment : Evaluation of risky factors related to product and manufacturing ,

Techniques to assess such factors , using statistical techniques in the assessment ,
connection with the latest technology , evaluating quality and manufacturing
processes, use of analytical outcomes and declaration of refining advices .

• Standardization : Processes and result of building , amending and terminating

standards , details of standards and their use , utilisation of statistical techniques and
proper use of technology .
• Benchmark : Procedures of quality control , offering to performance of quality circle
tasks , states of control tasks , conditions of issues in benchmarking .
• Quality Concern : NPD techniques which consists of designing , manufacturing ,
control , storage , supply , etc .
• Impacts : Impacts determined from concerning product quality , the level of product
improvement from concern of quality , quantity and costings and merging of effects .

• Strategy for future : Assessment of strength and weakness of the company , grasping
of present situations and identifying , rectifying defects , evaluating the advancement
of total quality management .

Thus , these are the Deming criteria for Performance Excellence with reference to quality
awards .