Module 1: Foundations of World Class Manufacturing

• What is World Class Manufacturing — origins and purpose
• From Toyota Production System to global WCM methodology
• WCM vs. Lean vs. Six Sigma vs. TQM — how they relate and differ
• The business case for WCM — competitiveness, cost, and quality impact

Module 2: The WCM Pillar Framework

• The 10 Technical Pillars and 10 Managerial Pillars — structure and logic
• How the pillars interconnect and support one another
• The WCM audit and scoring system (Bronze, Silver, Gold, World Class levels)
• Roles and responsibilities across pillar teams

Module 3: Technical Pillar 1 — Safety

• Building a zero-accident culture
• Hazard identification, risk assessment, and near-miss reporting
• Safety audits, standard safety procedures, and behavioral safety
• Safety KPIs and continuous improvement in workplace safety

Module 4: Technical Pillar 2 — Cost Deployment

• Linking losses and waste directly to financial cost
• The Cost Deployment matrix — Matrix A, B, C, D, E, F
• Prioritizing improvement projects by cost impact
• Tracking savings and validating financial results

Module 5: Technical Pillar 3 — Focused Improvement

• Identifying and eliminating major losses systematically
• The PDCA and DMAIC problem-solving cycles in WCM
• Root cause analysis tools — 5 Whys, Fishbone, Pareto Analysis
• Kaizen events and structured improvement projects

Module 6: Technical Pillar 4 — Autonomous Maintenance & Workplace Organization

• 5S as the foundation of workplace organization
• Operator-led equipment care and cleaning-as-inspection
• Step-by-step Autonomous Maintenance implementation
• Visual management and standard operating procedures

Module 7: Technical Pillar 5 — Professional Maintenance

• Total Productive Maintenance (TPM) fundamentals
• Preventive, predictive, and reliability-centered maintenance
• Overall Equipment Effectiveness (OEE) — measurement and improvement
• Maintenance planning, spare parts strategy, and breakdown analysis

Module 8: Technical Pillar 6 — Quality Control

• Deming's and Shingo's quality philosophies in practice
• Statistical Process Control — control charts, process capability, and variation
• Poka-Yoke (error-proofing) and mistake-proofing design
• Quality Function Deployment (QFD) and Failure Mode Effects Analysis (FMEA)

Module 9: Technical Pillar 7 — Logistics & Customer Service

• Value Stream Mapping across the end-to-end supply chain
• Just-in-Time production and Kanban pull systems
• Inventory reduction and material flow optimization
• Customer service levels and delivery performance metrics

Module 10: Technical Pillar 8 — Early Equipment & Product Management

• Designing for manufacturability and maintainability
• Vertical start-up and equipment commissioning best practices
• Cross-functional collaboration between design and manufacturing
• Lessons-learned integration into future equipment design

Module 11: Technical Pillar 9 — People Development

• Skills matrices and structured competency development
• Cross-functional teams and multi-skilling on the shop floor
• Training systems and capability-building programs
• Measuring the impact of people development on pillar performance

Module 12: Technical Pillar 10 — Environment

• Environmental management systems in a WCM context
• Waste, emissions, and resource consumption reduction
• Sustainability and ESG integration into manufacturing operations
• Environmental KPIs and regulatory compliance

Module 13: The 10 Managerial Pillars

• Managerial Pillar 1.  Management Commitment
• Managerial Pillar 2. Clarity of Objectives
• Managerial Pillar 3. Roadmap to WCM
• Managerial Pillar 4. Allocation of Highly Qualified People to Model Areas
• Managerial Pillar 5. Organizational Commitment
• Managerial Pillar 6. Competence of Organization Toward Improvement
• Managerial Pillar 7. Time and Budget
• Managerial Pillar 8. Level of Detail
• Managerial Pillar 9. Level of Expansion
• Managerial Pillar 10. Motivation of Operators

Module 14: Lean Manufacturing Toolkit

• Toyota Production System principles in depth
• Muda, Mura, and Muri — the three forms of waste
• Single-Minute Exchange of Die (SMED) and quick changeover
• Kaizen, Kanban, and continuous flow techniques

Module 15: Statistical Tools for WCM

• Basic statistics — central tendency, spread, and distribution
• Control charts and process capability analysis
• Data collection, sampling, and summarizing techniques for shop-floor decisions
• Using statistical evidence to prioritize and validate improvements

Module 16: Digital Manufacturing & Industry 4.0 in WCM

• IoT-enabled shop floors and real-time production monitoring
• Digital twins and predictive analytics for maintenance and quality
• AI/ML applications in defect detection and demand-driven production
• Integrating digital tools with traditional WCM pillars

Module 17: WCM Implementation & Case Studies

• Building a WCM implementation roadmap for an organization
• Common implementation barriers and change management strategies
• Case studies — global (Toyota, FCA/Stellantis plants, Unilever) and Indian manufacturing examples
• Lessons learned from failed vs. successful WCM rollouts

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