World Class Manufacturing (WCM)

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Q.1 How would you define World class manufacturing?
WCM is a collection of concepts known as world-class manufacturing establishes a benchmark for production and manufacturing that other organizations can follow.
Q.2 Name some techniques of WCM.
  • Make to order
  • Streamlined Flow
  • Smaller lot sizes
  • Collection of parts
  • Doing it right-first-time
  • Cellular or group manufacturing
  • Total preventive maintenance
  • Quick replacement
  • Zero Defects
  • Just in Time
  • Increased consistency
  • Higher employee involvement
  • Cross Functional Teams
  • Multi-Skilled employees
  • Visual Signaling
  • Statistical process control
Q.3 What are World Class Companies?
World-class companies are defined as those who can compete through manufacturing by developing multiple capabilities all at once. Multiple improvements within a value chain of suppliers add up, and should ultimately provide a cumulative competitive advantage to the OEM
Q.4 Although world-class manufacturers use rigorous control mechanisms, there are five actions that can be taken to make the system more efficient. Explain them to me.
  • Reduced set-up and tuning time: It's critical for businesses to be able to save time when it comes to setting up machines and adjusting them before they go into production.
  • Cellular Manufacturing: It's critical that manufacturing processes are split into categories based on their nature, with related operations grouped together.
  • Reduce WIP material: Manufacturing companies have a natural tendency to keep large amounts of WIP material on hand. WIP increases costs, while WIP decreases attention on manufacturing and allows for faster circulation of goods.
  • Delay product mutation: To reach a higher level of personalization, several alterations to the final product are done. It is critical, however, that mutations suggested during the design stage be implemented only after the final operation.
  • Remove the unimportant many and concentrate on the critical few: It is critical for businesses to concentrate on producing items that are in line with expected demand in order to meet client expectations.
Q.5 What are the principles of WCM?

World-class manufacturing is guided by three main ideas.

  • Implementing just-in-time and lean management reduces wastage, lowering costs.
  • Total quality management reduces defects and develops a zero-tolerance attitude toward them.
  • Total preventative maintenance is used to prevent production from being halted due to mechanical breakdown.
Q.6 Explain the aspects of WCM.

The following are the main characteristics of world-class manufacturing:

  • Area of industrial culture
  • Area of the market/client
  • Area of product development
  • Area of operations
  • Area of E-Performance
Q.7 What are characteristic of world class organization?
  • Customer Service Quality
  • Control and Assurance Innovation
  • Political Lobbying
Q.8 How has WCM evolve?
In recent years, the WCM market has undergone substantial transformations. Businesses moved away from contributing content to websites without a defined aim in mind to exploiting content as a cash generator. The way individuals access and consume material, services, and digital experiences has influenced the evolution of WCM. WCM requirements in today's world are more dynamic, connected, and interactive. Content can no longer be attached to a certain channel due to the development of digital marketing and the proliferation of channels such as mobile, email, social, digital kiosks/displays, wearable's, and messaging platforms. The emphasis has evolved away from compartmentalized WCM platforms and toward providing an end-to-end digital experience that includes analytics, personalization, and e-Commerce.
Q.9 What are the Practices of WCM?
World class manufacturing practices basically includes total quality management, total productive maintenance, 5S, supply chain management, lean manufacturing, just in time manufacturing.
Q.10 Explain quality in World-Class Manufacturing.
World Class Manufacturing (WCM) is a cutting-edge concept used by business leaders around the world. One of the nine pillars in this notion is directly tied to quality, while the other eight are indirectly related to it. As a result, it's critical to look at the connections between this concept and the concept of quality model.
Q.11 What is Deming's Approach?
When it came to process analysis and improvement, Deming advocated for the Plan-Do-Check-Act method. Emphasize training and education so that everyone can perform better at their employment. Use kaizen as a model to cut waste and boost efficiency, effectiveness, and safety.
Q.12 Explain Shingo’s Approach.
The Shingo Guiding Principles serve as the foundation for establishing a long-term corporate excellence culture. The principles are split into three dimensions in the Guiding Principles diamond: Cultural Enablers, Continuous Improvement, and Enterprise Alignment.
Q.13 What is Frequency Distributions?
A frequency distribution is a graphical or tabular representation that shows the number of observations within a specified interval. The interval size is determined by the data being examined and the analyst's objectives. The intervals must be mutually exclusive as well as comprehensive. In most cases, frequency distributions are utilized in a statistical setting. In general, the charting of a normal distribution is connected with frequency distribution.
Q.14 Explain Central Limit Theorem.
The central limit theorem (CLT) asserts that as the sample size grows higher, the sample distribution approaches a normal distribution (commonly known as a "bell curve"), provided that all samples are equivalent in size and regardless of the population distribution shape. CLT is a statistical theory that states that given a sufficiently enough sample size from a population with a finite level of variance, the mean of all samples from the same population will be about equal to the population mean. Furthermore, all of the samples will have a roughly normal distribution.
Q.15 Define Probability.
Probability is a discipline of mathematics concerned with numerical explanations of the likelihood of an event occurring or the truth of a claim. The probability of an event is a number between 0 and 1, with 0 indicating the event's impossibility and 1 indicating certainty.
Q.16 What is Control Chart?
Control charts, also known as Shewhart charts or process-behavior charts, are statistical process control tools that are used to establish if a manufacturing or business process is under control. Control charts are more accurately described as the graphical device for Statistical Process Monitoring.
Q.17 Explain Toyota Production System.
The Toyota Production System (TPS) is a Toyota-developed integrated socio-technical system that includes its management philosophy and practices. The TPS is a management system for vehicle manufacturers that coordinates manufacturing and logistics, as well as interactions with suppliers and customers.
Q.18 What is the Lean manufacturing?
Lean manufacturing is a methodology for improving processes based on the well-known Toyota Production System (TPS). The elimination of waste from a value stream is the core focus of lean manufacturing. In this case, waste is defined as anything that consumes resources while providing no value to the client. When waste is removed from a value stream, it is possible to produce only the proper material, in the quantity needed by the client, at the precise right moment. As a result, the process is more efficient, and the product is delivered to the consumer faster. The parts of a value stream that bring value to the consumer usually make up a tiny percentage of the total.
Q.19 Define Mudas.
Mura means "overload" or "burden." It refers to working something over its capability, whether it's factory equipment or your workforce. Working anything above its capacity might result in a gradual decrease in output or possibly a complete shutdown. This can be disastrous depending on your industry and the nature of the systems in place.
Q.20 What is Value Stream Mapping?
The value stream mapping method allows you to visualize all of the processes in your work process in great detail. It is a diagram that depicts the flow of goods from the supplier to the client within your company. A software company, for example, provides value to its customers in the form of software solutions and all features contained within.
Q.21 Explain 5S in WCM.
The 5S system is a lean manufacturing technology that reduces waste and increases workplace productivity.
Q.22 What is Kaizen?
Kaizen is a Japanese corporate philosophy involving practices that continuously improve operations and involve all personnel. It is a Japanese term that means "change for the better" or "continuous improvement." Kaizen views productivity development as a thorough and steady process. Kaizen is a broad concept that incorporates a variety of principles. It entails building a team attitude, refining daily operations, assuring employee involvement, and making a job more satisfying, less stressful, and safer.
Q.23 Explain Single Minute Exchange of Die (SMED).
SMED (Single-Minute Exchange of Dies) is a technique that drastically reduces the time it takes to replace out equipment. The SMED system's goal is to make as many changeover procedures as possible "external" (done while the equipment is running), while simplifying and streamlining the rest.
Q.24 What is Kanban Card System?
A Kanban card is a depiction of a work item in visual form. It literally translates to "visual (kan) card" in Japanese (ban). It's an important part of the Kanban system because it indicates work that's been requested or is already underway.
Q.25 What is Total Productive Maintenance?
Total Productive Maintenance (TPM) is a method of equipment maintenance that attempts to improve productivity, efficiency, and safety in order to produce a perfect manufacturing process. Zero unplanned failures, zero product defects, and zero accidents are the three aims of TPM. These objectives are furthered by applying eight "pillars" aimed at increasing productivity by ensuring reliability in the manufacturing process. A emphasis on providing a safe work environment through a planned workplace safety improvement strategy is one of these pillars. Employees are involved in developing workplace safety standards and maintaining a safe work environment as part of this process.
Q.26 Explain Strategic Planning Issues for WCM.
Strategic planning is the process of developing specific business plans, putting them into action, and analyzing the results in terms of a company's overarching long-term goals or wants. It's a notion that focuses on a company's strategic goals being met through integrating several departments (such as accounting and finance, marketing, and human resources). The terms "strategic planning" and "strategic management" are almost interchangeable.
Q.27 What are the Strategic Barriers for IT?
Market structure barriers are likely to drive enterprises to respond strategically. In other words, if firms believe that market barriers are insufficient to deter market entry, they might take tactical efforts to prevent new competitors from entering the market and safeguard their market position. As illustrated in some of the examples below, such behaviors might raise ethical and legal concerns.
Q.28 What are the Shingo Guiding Principles?
Respect Every Individual Lead with Humility Seek Perfection Embrace Scientific Thinking Focus on Process Assure Quality at the Source Improve Flow & Pull Think Systemically Create Constancy of Purpose Create Value for the Customer
Q.29 Explain Frequency Distribution.
A frequency distribution is a statistical tool that offers a visual depiction of the distribution of data within a test. Frequency distribution is frequently used by analysts to depict or interpret the data obtained in a sample. Children's height, for example, can be divided into numerous groups or ranges. When 50 children's heights are measured, some are tall and some are small, but the medium range is likely to have a larger frequency or concentration. The most critical aspects of data collection are that the intervals employed do not overlap and that all possible observations are included.
Q.30 What is performance gap?
A performance gap is the difference between the existing situation's performance and the desired situation's performance. It's the difference between what the target person or team does and what the firm anticipates.
Q.31 What are the benefits of value stream mapping?
You can identify wasteful actions with the help of VSM. VSM gives you a clear picture of the work process, including where value-adding and non-value-adding stages are formed. Visualizing how long it takes for work items to pass through them is also a valuable exercise. VSM emphasizes the present workflow while focusing on future enhancements.
Q.32 What are the steps of 5S?
Since 5S was developed in Japan and the original "S" phrases were written in Japanese, English translations for each of the five steps may differ. However, the fundamental concepts and linkages between them are simple to grasp. Name of the step Explanation of the Japanese phrase 1. Sort Seiri (tidiness) Remove any items that aren't needed from each location. 2. Seiton (orderliness) Organize and identify storage for efficient use. 3. Clean and inspect each area on a regular basis to maintain the Shine Seiso (cleanliness). 4. Seiketsu (standardisation) should be standardised, and 5S should be incorporated into standard operating procedures. 5. Maintain Shitsuke (discipline) through assigning responsibilities, keeping track of progress, and repeating the cycle.
Q.33 What are the requirements for Kaizen?
Teamwork, personal discipline, better morale, quality, and suggestions for improvement are the five main elements of traditional Japanese kaizen ideas. Three important effects result from these five tenets: waste removal (also known as economic efficiency), excellent housekeeping, and standardisation. Kaizen should, in theory, become so established in a company's culture that it becomes second nature to personnel. The kaizen philosophy asserts that there is no such thing as perfection and that everything can be improved. People must continuously seek to adapt and innovate.
Q.34 What are the steps to Implement SMED?
Identify The Process Identify Elements Separate External Elements Convert Internal to External Streamline
Q.35 Give an example of SMED.
During professional motor racing, one real-life example of SMED can be witnessed. For race car drivers, the quickness of pit crews can sometimes mean the difference between winning and losing. Pit staff frequently videotape each pit stop, looking for ways to reduce the amount of time a car spends in the pit lane. The amount of time spent on each activity — changing tyres, cleaning windshields, and pumping gas – is calculated. Another occurs on a daily basis in the restaurant sector. Many restaurants provide breakfast, lunch, and supper menus. As cooks prepare for various dinners and (in some situations) one serving staff clocks out while another clocks in, switching from one to the other might take up to an hour. This process can be sped up to provide for a better transition between serving times. Restaurants have gotten so skilled at it that they now offer products from two – or even all three – menus at any time of day.
Q.36 Which types of machinery are you most experienced with?
Even though the types of machinery that you are experienced with may be specified on your resume yet the interviewer would like to evaluate your exposure to certain types of machinery. Ensure that you should have a good understanding of the type of machinery. Sample Answer - You may start by saying that - The machinery I am most experienced with would be A, B, and C. As an expert in using these types of machinery used by top The World Class Manufacturing Group, Inc. I assure for best results. Are you looking for any specific type of machinery?
Q.37 What do you understand by cutting edge machinery?
The focus of the interviewer is to be assured that you have done enough research on The World Class Manufacturing Group, Inc. You should be well prepared before attending the interview. Sample Answer - Start by saying that you have done enough research n World Class Manufacturing this fact indicates high quality and more local employment opportunities. Support by giving relevant examples and experience
Q.38 How will the knowledge gained from your most recent position help you succeed in this role with The World Class Manufacturing Group?
Focus of the interviewer is to know about your skills and knowledge you have gained in your current role and how those skills will help you to succeed in this position. It is suggested to start with the core skills mentioned in job description and di8scuss about how you currently exercise those skills. Sample Answer - As I could see you are looking for a candidate with strong leadership skills and in my previous job I lead a team of 20 technicians with great output. Since taking a leadership role with my current company, our productivity has increased by 35%, and our employee turnover has decreased by 40%. Therefore I am confident to apply my leadership successes to this role and excel given the opportunity.
Q.39 What is the role of maintenance In maintaining?
The primary role of maintenance in maintaining asset value over time is to get more visible at the business level with the increase in its acquisition and maintenance costs.
Q.40 What do you understand by maintenance load forecasting?
Maintenance forecasting is considered as a major part of planning concerned with estimating the current and future amount of maintenance work and type needed. Such that maintenance load forecasting is considered as a complex task which involves a lot of uncertainties and influenced by many factors like age of the equipment, rate of use, usage, skills of workers and climate.
Q.41 What does the CIM anticipates?
CIM anticipates reintegration of special expertise organized in functional departments through integrated information process.
Q.42 Which is the initial step in Kanban implementation?
The initial step in Kanban implementation is mapping value stream.
Q.43 When is moving range chart used?
Moving Range chart is used with limited data, such as when production rates are slow, testing costs are very high, or there is a high level of uncertainty relative to future projects.
Q.44 Where does the target should ideally be located under process standard deviation?
The middle point between USL and LSL.
Q.45 What does Total Productive Maintenance on?
Total Productive Maintenance focuses on proactive and progressive maintenance of equipments by utilizing the knowledge of operators.
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