WCM

INTRODUCTION

CHRIS BAKER
GROUP MANUFACTURING EXCELLENCE CAPABILITIES
MANAGER

English, live in Manchester.

Joined Unilever in 1997.
2 Children.

Operational Background from

SUs.
Electrical Engineer by training.
Key Roles:Project Manager
Technical Manager
Operations Manager
Quality Improvement Project

What is WORLD CLASS

MANUFACTURING
?
World
Class Manufacturing
(WCM) is a structured and
integrated production system
that involves all sites processes
and the entire organization from
top to shopfloor people.

WCM target is to
continuously improve
sites performance
eliminating waste &
losses.

People
Development

Environment

Level of
expansion

Motivation of
operators

Logistics &
Customer
Service

Quality

Professional
Maintenance

Autonomous
Activities

Focus
Improvement

Cost
Deployment

Safety

EEM & EPM

10 Managerial Pillar

Level of
details

Time &
Budget

Competence
of the
organization

Commitment
of the
organization

Allocation of
highly
qualifed
people

Route map to
WCM

Clarity of
objectives

Management
Commitment

WCM Pillars
10 Technical Pillars

WCM is not.
.WCM is
WCM is

WCM is NOT
A project

A program, a way of working

A toolkit of methods and tools

Integrated production system

Restructuring program

Continuous learning-improvement

A technical job for operators and

program

engineers

A leadership and management

Top-down OR bottom up

program

An activity oriented program

Top-down AND bottom-up approach

Cost cutting program

A results oriented program

A safety-quality and productivity
improvement program

The Toyota style is not to create results by working hard.

It is a system that says there is no limit to peoples
creativity. People dont go to Toyota to work they go
5
there to think - Taiichi Ohno

WCM Pillar approach

7
steps
Pillar score

0-5

reactiv
e

proactiv
preventi
ve

WCM Pillar Approach

Model Area selection: most critical

Model Area
Implementation

area, with highest losses for each specific

pillar
Safety = highest accidents/incidents

7 Steps
Expansion

area
AM = highest BDs losses due to lack of

Application of pillar

basic conditions

7 steps approach

PM = highest BDs losses due to lack of

in Model Area to

maintenance
Other Areas
Extension
Extension in other areas

After reaching a certain step in the model

area, same approach is applied in other areas.
AM = after reaching step 3 in model area with
proved results team expand AM in the second
most critical area

create knowledge

WCM Score: 0-100 points

Gold
Silver
Bronze
Beginne
1rs
49

pts

5059

pts

Establish the basic

conditions for
competitive
manufacturing
10 20% cost
reduction

1 year

2 years

70-84
pts

6069

pts

Achieve a
substantial gains
in Q, C and D in
manufacturing
competence.
25 40% cost
reduction

3 years

Be the WC leader
in Q, C and D in
business.
ca. 50% cost
reduction

4-5
Years

World
85Class
100

pts

WCM Ambition
Growing skills and Capability Zero Gaps
Zero Accident & Zero First Aid
Zero machine breakdown
Zero quality defects
Zero customer claims
Zero minor stoppages
Zero waste & losses

WCM Audits Completed

Last Score
38

# Audits

37
31

31
25

24
20
17
14

14

13

13
11

11
9

4
1

4
1

Increasing the speed

to meet business
opportunities

TECHNICAL SKILLS UPGRADE IS

PIVOTAL TO ELIMINATE LOSSES AND
WASTE IN OUR LINES
Top Losses

(WCM sites)