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Challenge to world-class manufacturing

H. Yamashina

The author argues that the first step to world-class manufacturing is to implement TPM successfully and

to create a very active organization. When TPM has became a common practice in daily production, it can be

said that the company commenced a journey to world-class manufacturing. Compare Japan and continous

technological developments with the West and American manufacturing; Japan, over the years, has

dramatically improved its production process and management of quality management, a primary basis for

developing the best product when considering meeting consumer needs.

Manufacturers have faced many challenges in the last 30 years, as increased competition in markets

around the world, the demand for more complex products and consumer pressure for more options in the goods

produced have found that diversification is the key word that manufacturing firms, today, have in mind to

satisfy the customer; mass customization is now the target of many manufacturers. Everyone wants to buy an

item of superior quality, but at a higher price. To meet these challenges, manufacturers have had to look at all

aspects of the way we do business. To remain competitive, manufacturers must:

 Understand the business trends that are driving the global economy, employing proven and effective

management practices and processes.

 Implement proven manufacturing technologies and supporting software; and

 Appreciate and employ the world-class human resource practices that are attracting today’s best talent

and making “best-in-class” companies even more fierce in terms of intellectual capital and skill

capabilities.

Manufacturers strive to fulfill the best process faster and cheaper production of the current economy.

These new ideas, designs and ways of doing things are sought. Aspects of the production, identification of time
or skill aspects are examined demanding and looking for ways to improve those processes. The challenges for

companies related to products, processes and people. Drivers are in manufacturing technology and knowledge.

Manufacturing is continually being reinvented, thanks to improvements in manufacturing technologies.

New technologies drive new ways of thinking about the processes, systems and objectives. Those have

led to new innovative applications, and improvements in manufacturing technology. Improvements in machine

and tool materials have resulted in faster production of higher quality products. Those, combined with reduced

setup times, have helped advanced manufacturing processes economically viable. Intelligent machines

combined into a better, more efficient have helped companies reduce labor requirements, inventories and plant

size, while improving product quality and reducing rework rate. They were as follows:

 Using collaboration for competitive positioning

 The importance of effective management practices of supply chain

 Mass customization and smart consumers

 Globalization of markets

 Emergence of the virtual enterprise

Collaboration between groups design, manufacturing and support within an enterprise and a supply

chain is becoming essential. Collaborative engineering tends to minimize lead times, design changes, the use of

critical processes, unit costs, product variability and realistic tolerances. Promotes maximum standardization,

knowledge of the supplier, the predictability of the process and design simplicity.

Moreover we have global manufacturing, a component of the collaborative manufacturing resources

being used worldwide to produce identical or similar parts, components and sub-assemblies with the same

quality, at the same time and comparable cost structures. The manufacturers go global to expand into new

markets, to carry out the design and manufacture worldwide, take advantage of local resources and technology

worldwide.

In conclusion, in the manufacturing sector need TQM, JIT and TPM. From a conceptual point of view,

the TPM is a part of TQM. The JIT can not be implemented without TPM. Therefore, the TPM is a base of JIT.

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