18ME652 World Class Manufacturing syllabus for ME

Historical Perspective World class Excellent organizations – Models for manufacturing excellence: Schonberger, Halls, Gunn and Maskell models, Business Excellence.

Benchmark, Bottlenecks and Best Practices, Concepts of benchmarking, Bottleneck and best practices, Best performers – Gaining competitive edge through world class manufacturing – Value added manufacturing – Value Stream mapping – Eliminating waste –Toyota Production System –Example.

System and Tools for World Class Manufacturing. Improving Product & Process Design – Lean Production – SQC, FMS, Rapid Prototyping, Poka Yoke, 5-S,3 M, JIT, Product Mix , Optimizing , Procurement & stores practices , Total Productive maintenance, Visual Control.

Human Resource Management in WCM:

Adding value to the organization– Organizational learning – techniques of removing Root cause of problems–People as problem solvers–New organizational structures. Associates–Facilitators– Teamsmanship–Motivation and reward in the age of continuous improvement.

Typical Characteristics of WCM Companies Performance indicators like POP, TOPP and AMBITE systems– what is world class Performance –Six Sigma philosophy. Indian Scenario on world class manufacturing –Task Ahead. Green Manufacturing, Clean manufacturing, Agile manufacturing.

Course Outcomes:

At the end of the course, the student will be able to:

CO1: Understand recent trends in manufacturing.

CO2: Demonstrate the relevance and basics of World Class Manufacturing.

CO3: Understand customization of product for manufacturing.

CO4: Understand the implementation of new technologies.

CO5: Compare the existing industries with WCM industries.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.  There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.

Textbook/s

1 World Class ManufacturingStrategic Perspective Sahay B.S., Saxena KBC. and Ashish Kumar Mac Milan Publications New Delhi

2 Just In Time Manufacturing Korgaonkar M.G MacMilan Publications

Reference Books

1 Production and Operational Management Adam and Ebert Prentice Hall learning Pvt. Ltd. 5th Edition

2 The Toyota Way – 14 Management Principles Jeffrey K.Liker Mc-Graw Hill 2003

3 Operations Management for Competitive Advantage Chase Richard B., Jacob Robert McGraw Hill Publications 11th Edition 2005

4 Making Common Sense Common Practice Moore Ron Butterworth-Heinemann 2002

5 World Class Manufacturing- The Lesson of Simplicity Schonberger R. J Free Press 1986