1. World Class Manufacturing Purple HR Consulting Private Limited 104, Maple Wood Opp. Aga Khan Palace Yerawada, Pune: 411 006 www.purplehrconsulting.com sudhirsohoni@purplehrconsulting.comsudhirsohoni@purplehrconsulting.com +91 9823010099 sudhirsohoni@purplehrconsulting.com

2. World Class Manufacturing What is World Class Manufacturing ? World Class Manufacturing depends on martialing resources for continual rapid improvement. This involves recasting relationship among Suppliers, Purchasers, Producers and Customers. - Prof. Richard Schonberger - 1986 Copyright © 2013.All Rights Reserved with Purple.

3. Industrial Growth with Mechanization, Productivity Increases Substantially 19271922 Factories Redesigned for better use of Electric Motors 1938 US Industrial Production Develops 1941 World War II 1947 Search for Low Cost Manufacturing Areas 1949 R&D Departments Widespread 1951 Exploiting Wartime Innovations 19541955 SQC for Acceptable Defect Level 1959 Project Evaluation and Review Technique 1961 / 62 Critical Path Method (CPM) 1971 / 72 Focused Factory 1979 Robotics and Numerical Control 1981 Six Sigma – Motorola 1982 Computer Assisted Design 1983 / 84 Statistical Process Control for Quality 1986 Lean Manufacturing 1989 / 90 Benchmarking ISO Standard 1992 Process Re- Engineering and Outsourcing 1994 Supply Chain Management 1995 Six Sigma Central in Strategy 1996 World Class Manufacturing Manufacturing Excellence Initiatives Over Last 90 years

4. World Class Manufacturing How each of these initiatives deferred?  IE : Zero Waste  TQM : Zero Defect  TPM : Zero Default  JIT : Zero Stock  TEI : Zero Injury Copyright © 2013.All Rights Reserved with Purple. WCM : Integrates IE,TQM, TPM, JIT, TEI, Six Sigma, Lean & Kaizen

5. World Class Manufacturing What is Unique?  Flexible Logistics  Rapid Changeover and Machine Flexibility  Focus on quick New Product Development  Inspection Eliminated  Empowered Workers – Problem Solving, Widespread Idea Contribution Copyright © 2013.All Rights Reserved with Purple.

6. World Class Manufacturing What will your company achieve by adopting WCM?  Customer Satisfaction  Assured Quality  Quick and On Time Deliveries  Maximize Inventory Turns  Highly Engaged Workforce  Least Cost Manufacturing Copyright © 2013.All Rights Reserved with Purple.

7. World Class Manufacturing How will we make it happen? Step 1 : Through Diagnostic Step 2 : Identification of Priorities – Creating a Work Plan Step 3 : Widespread Workforce Involvement Step 4 : Structured Problem Solving Step 5 : Weekly, Monthly, Quarterly Reviews segmented on Lead Time Articulation Copyright © 2013.All Rights Reserved with Purple.

8. People in Purple Copyright © 2013.All Rights Reserved with Purple. Sudhir Sohoni Sudhir is an alumnus of TISS 1980 Batch and in his 30 years worked with WIMCO, Metal Box India, Hindustan Unilever, RPG Group and Thermax. For the past 15 years has been working at the strategic level and holds expertise in designing organizations for growth and profitability. He is the Founder of Purple HR Consulting. Anup Gandhi Anup is a seasoned, 30+ years experienced hard core manufacturing person, managed heavy engineering factory set up with 1200+ workforce, as a factory manager. Anup is a Mechanical Engineer graduated from Govt. College Of Engineering, Amravati, Nagpur University ( 1979) & done Master in Management Science ( MMS) from Symbiosis Institute; Pune University (1984). Anup has undergone intensive coaching from Japanese Sensai Mr. Takao Kasahara San, Mr. Masaki Imai San & Indian Sensai Mr C Narsimhan on the Manufacturing Excellence Programs. He has implemented TQM, TPM, Lean and Kaizen in manufacturing and office environment.

9. People in Purple Copyright © 2013.All Rights Reserved with Purple. Shivangi Page Shivangi is an alumnus of St. Xavier’s College Mumbai from where she graduated in Sociology and completed her MPM from IndSearch Institute under Pune University. She joined Thermax as a Management Trainee and did some path- breaking work in Industrial Relations followed by a stint in Business HR before heading Corporate HR. she has her expertise in Design and Conducting of the Assessment / Development Centers as well as in Employee Engagement besides being an outstanding training faculty. Shivangi is the Founder Member of Purple HR Consulting. Rajasi Lonkar Rajasi is a graduate in Hotel Management from the University of Pune. Thereafter she worked for a year in The Oberoi, Mumbai. Rajasi completed her MBA-HR from the University of Pune in May 2013. She joined Purple as Associate Consultant and provides effective support in the conduct of Company Diagnostic Study, HR Process Reviews, and independently handles Data Analysis, Back end work

10. World Class Manufacturing Copyright © 2013.All Rights Reserved with Purple.

11. Thank you Exercise on Job Analysis