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Good Governance & Making People/Organisations More Competent

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A. M Singhvi,FCA, ACMA, PhD, DEng T:(+44)7872012815, (+91)9663375847 E:asinghvi_london@yahoo.com www.dollar-a-day-singhvi.blogspot.com

World Class Manufacturing for Competitive Advantage

You will be challenged to stretch yourself intellectually beyond areas you’ve mastered in the past.
This Course is designed to give you the analytic skills and intellectual framework you will need to succeed over a lifetime in the changing global business environment. Work is spread over 3 months, allowing time for you to explore and absorb new ideas that will meet long-term goals and develop individual skills to diagnose complex issues, devise solutions, and apply them.
Dynamic and innovative, this course reflect the latest research, both theoretical and fieldbased, and help participants develop fresh perspectives. The goal of the World Class Manufacturing curriculum is not to identify best practice or prescribe fixes for today’s business problems, but rather to identify underlying principles that will help participants operate effectively today and for decades to come.
A comprehensive Road Map has been designed specifically for WCM Champions. Taken together, these are the building blocks that challenge participants to stretch beyond their past experience to grasp new ideas and develop a better understanding of the processes used by successful senior managers. In addition to the core courses

The WCM Program is:

• A three -month academic program part of Good Governance Initiative, leading to a Certificate of WCM Champion.
• Tailored to the needs, see below.

The WCM Program is designed to:
• Encourage a broader perspective that will make you a more effective manager and encourage a pattern of lifelong learning and personal growth to prepare you for top management positions.
• Develop a deeper understanding of fundamental management concepts, both through functional approaches, such TPM, TQM, Six Sigma, BPR, Advanced Problem Solving Methods and in cross-disciplinary work that encourages new approaches to business issues.
• Explore the increasingly global nature of the economic, social, political, legal, and ethical responsibilities of management.
• Expand your abilities in group and interpersonal relationships through both peer group interaction and academic work in leadership and related fields.

Within the WCM Program , you will be part of a hard-driving yet collaborative group. Your classmates’ wide range of professional experience will help you take a broader look at management questions, share and explore new ideas that strengthen the management skills you take back to your company. Your courses, taught by the WCM renowned faculty, will offer the tools and broad concepts you need to succeed as you assume more management responsibility in a world undergoing major social, political, and economic change.

A Dynamic Curriculum
The WCM curriculum is a part of a continuous process of change. World-class, dynamic, forward-looking, and innovative, WCM curriculum is enriched constantly as it incorporates new ideas. You will have the tools you need to set yourself apart as a manager, plus a solid framework of knowledge that will help you adapt the new ideas you


Once through the core, you will have an opportunity to shape the program to fit your needs through electives. You might study the role of WCM in business, managing change, or manufacturing strategy. Roughly half the elective courses are new or substantially revised every five years, reflecting both changes in the business world and academic research. Examples of courses are Theory of Constraints, Six Sigma, Robust Engineering, BPR etc.

Who can join us?
Employees at all levels to leap frog their careers and performance. Owners to make the best use of resources and opportunities to improve. Unemployed wanting to improve their capabilities to compete and secure good jobs.

Course Duration: Need based. Course Details

Week 1

Topic: Quality and Manufacturing Approaches for the New Millenium
Duration: 4 Days

1. Contemporary Quality Initiatives/ Systems / Techniques
2. Overview: TPM, BPR, TPS, TQM, TQC
3. International Organization for Standardization
4. International Quality Rating System
5. Theory of Constraints
6. Six Sigma
7. Risk Management 8. Benchmarking

Topic: Introduction to World Class Manufacturing
Duration : 2 days

1. The WCM Approach
2. WCM Excellence Model for Competitive Advantage
3. The Eight Dimensions and Fourteen KMFAs
4. WCM Methodology
5. Eight Types of Abnormalities: Concept and Exercise

Week 2

Topic: Waste Elimination

Duration : 2 days

1. Concept of Waste

2. Twelve types of Wastes

3. How to eliminate Waste

Topic: Work Environment [5S}

Duration 2 Days

1. Definition

2. Advantages of 5S

3. Implementation of 5S Principles

4. Benefits of 5S

5. 5S Audit

Topic: JIT and Stock Reduction

Duration: 2 days

1. Evolution of JIT

2. Principles of JIT

3. JIT Approach v/s Traditional Approach

4. Pull v/s Push Systems

5. Kanban

6. Throughput Time Reduction Techniques


8. Direct on line Delivery

9. JIT for Suppliers

10. JIT Purchasing

11. Supply Chain Management

Week 3

Topic: Equipment Effectiveness

Duration: 1 Day

1. History of Equipment Management

2. TPM and its Salient Features

3. Concept of OEE and OPE

Topic: Focused Improvement and Kaizen

Duration: 1 Day

1. Kaizen v/s Innovation

2. Sixteen Types of Losses and Loss Structure

3. Loss Cost Matrix

Topic: Autonomous Maintenance

Duration: 2 Days

1. Autonomous Maintenance Goals

2. Role of Operations and Maintenance Departments

3. Know Your Equipment

4. Equipment Related Abnormalities

5. Seven Steps of Autonomous Maintenance

6. One Point Lesson

7. How to implement Autonomous Maintenance

8. AM Audits

Topic: Planned Maintenance

Duration : 2 Days

1. Techniques of PM

2. Concept of MTTR and MTBF

3. Equipment Evaluation

4. Maintenance Cost

5. Steps of PM

6. Reliability Centered Maintenance

7. Supporting AM Activities

Week 4

Topic: Initial Flow Control and MP Design

Duration: 1 Day

1. Introduction

2. 4 Steps of Initial Flow Control

3. MP Design

4. Concept of LCC

Topic : Safety, Hygiene and Pollution Control

Duration:2 Days

1. Importance of Safety, Hygiene and Pollution Control

2. Safety: The 3Ds

3. Safety and Autonomous Maintenance

4. ISO 14000: Environment Management System

5. Kiken Yochi Training

6. Emergency Handling Procedures

7. Employee Health Checkup

8. Good Hygienic Practices

9. Pollution Control

Topic: Strategic Quality Management

Duration : 3 days

1. Evolution of Quality

2. SQM and its elements

3. The SQM Model

4. External and Internal Environment Scanning

5. Goal Formulation

6. Strategy Formulation

7. Program Formulation

8. Implementation

9. Measuring and Monitoring

10. Cost of Quality

11. Quality Function Deployment

12. Basic Statistics

13. Statistical Process Control

14. Application of SPC

15. Poka Yoke

16. Six Sigma: The DMAIC Strategy

Week 5

Topic: Customer Driven External and Internal

Duration: 2 days

1. Market Orientation

2. External and Internal Customer

3. Customer Feedback System

4. Customer Delight

Topic: Liaison, Team Force and Skills Development

Duration: 2 days

1. Liaison

2. Team Building

3. Skill Development: Sill Charts

4. Career Mapping

5. Education, Training and Development

Topic:Information, Systems, Technology and Cash Flows

Duration: 2 days

1. Information: Types of Information, IT and its application

2. System Development

3. World Class Office Management

4. Cash Flows and Value Drivers

Week 6

Topic : Visual Management and Visual Controls

Duration: 2 days

1. Definition

2. Visual Factory

3. Visual Management Systems

4. Types of Visual Controls

Topic: Problem Solving Tools

Duration : 4 days

1. Why Why analysis

2. Brain Storming

3. Cause and Effect Analysis

4. PM Analysis


Week 7

Topic: Zero Abnormality Movement

Duration: 1 day

1. ZAM Defined

2. Eight Types of Abnormalities

3. Abnormality Management System

Topic : Implementing WCM and Managing Change

Duration: 2 days

Topic: Best Practices in Industries

Duration : 3 Days

Week 8

Topic: National and International Awards

Duration: 4 days

1. Rajeev Gandhi National Quality Award, CII Exim Award, Ramakrishna Bajaj National Award, Golden Peacock Award

2. Deming Prize, Malcom Baldrige National Quality Award, Shiego Shingo Prize, European Quality Award,

Topic: Chairman’s Awards for Manufacturing Excellence

Duration 2 days

Introduction, Award Categories, Benefits of Award Process, Award Framework, Award Criteria, Award Assessment, Scoring Guidelines
Project: To be selected by the student in consultation with the Instructor.
Duration : One Month
Certificate Examination: After successful completion of the three month.