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    "THE EFFECTIVE IMPLEMENTATION AND PRACTISES OF

    WCM" with special reference to Harihar Polyfibres

    CONTENTS

    1. INTRODUCTION AND DESIGN

    2. GRASIM INDUSTRIES LIMITED - A PROFILE

    3. WORLD CLASS MANUFACTURING

    4. WORLD CLASS MANUFACTURING METHODOLOGY

    5. WCM MODEL

    6. IMPLEMENTATION OF WCM IN HARIHAR

    POLYFIBRES

    7 SURVEY ANALYSIS AND FINDINGS, SUGGESTIONS

    AND CONCLUSION

    8 FINDINGS AND SUGGESTIONS AND CONCLUSION

    ANNEXURE

    Questionnaire

    Bibliography

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    CHAPTER 1

    INTRODUCTION AND DESIGN

    INTRODUCTION

    SCOPE OF THE STUDY

    OBJECTIVES OF THE STUDY

    METHODOLOGY OF THE STUDY

    LIMITATIONS

    STATEMENT OF PROBLEM

    CHAPTER SCHEME

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    INTRODUCTION

    When it comes to providing well-built product the

    company's strength lies in its people. They represent a

    vast fund of knowledge, experience and creative ideas

    resources that meet or create demand in the market.

    MEANING OF WCM (World Class Manufacturing)

    WCM is an insight into the concept of equipment

    ownership, maintenance, visual management and how

    these help one in gaining knowledge about the equipments

    he is handling, using and operating, maintaining etc.

    WCM helps in reducing or eliminate abnormalities

    wastes and looses by knowing the tools and techniques

    and by identifying them.

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    WCM is defined as "the process of ultimately gaining

    the common goal and achievements of the company by

    knowing appropriate ways to keep the environment in the

    best possible way to get the best out of the best plants".

    SCOPE OF THE STUDY

    Since the study is an attempt to examine the present

    status of WCM program by critically analyzing the concept

    of WCM it forms a link between what has been established

    and what is being implemented. The scope of the study is

    limited only to the management, staff and workers of

    Harihar Polyfibres. This study provides a theoretical

    framework to understand the basic concepts of WCM.

    Since the study, is an attempt to examine the

    present status of WCM function by critically analyzing

    some of the WCM practices in the unit it forms a link

    between what has been established.

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    The study has taken into account to assess those

    efforts that have been taken by Harihar Polyfibre to

    achieve WCM standards.

    The review of WCM climate seeks to click the

    perception of the people and hence reflects their feelings

    and attitudes towards the WCM program. This' may be

    used to set right the weakness and capitalize on strength.

    The analysis and objective feedback can in turn lead

    to fruitful action plans to further strengthen the WCM

    efforts in the organizations.

    OBJECTIVES OF THE STUDY

    1. To study and understand the concept of world-class

    manufacturing.

    2. To study the implementation of WCM in HPF.

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    3. To study overall effectiveness of WCM and impact of

    WCM practices towards changing the mindset, culture

    and passion of employees.

    4. To study the communication and training through the

    WCM practices

    5. To highlight the importance of WCM in the context

    process industry.

    6. To identify the reason for increasing emphasis on

    WCM.

    METHODOLOGY OF THE STUDY

    The study is based on survey technique. The study

    consists of analysis about WCM at HARIHAR POLYFIBRES.

    For the purpose of the study 18 employees were selected,

    their views were selected, and their views were solicited on

    different parameters.

    The methodology adapted includes,

    Questionnaire

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    Random samples survey of employees

    Discussion with the concerned employees

    Personal interviews and informal discussions were

    held with some

    Employees to ascertain the impact practices of WCM in

    the unit.

    LIMITATIONS

    The study is limited only to Harihar Polyfibres

    division only. The other unit [grasilene] could not be

    covered due to time constraint. The sample size was

    constrained by the time available for the study.

    WCM is a vast concept and a relatively new one. It

    varies from organization to organization and so it is not

    possible to include each aspect.

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    STATEMENT OF PROBLEM

    There is no field of management that will not benefit

    from systematic and purposeful research. The field of

    WCM is in great need of systematic knowledge and sound

    principles. This is a new area, which has come to this

    country after being successfully implemented in western

    manufacturing units or sectors.

    A separate entity is needed within an organization in

    order to align the people towards a common goal that is

    unified with the cooperation strategy unless employees

    ask new questions they shall not get different results only

    the companies that are high on performance as well as

    practice can become world class. This is where WCM cell

    appears. There is no end to improvement and here WCM is

    the next step towards manufacturing excellence.

    WCM program represents a unified theory

    compromising principles, methods, tools and system that

    are applicable to all the manufacturing units. It enables

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    the chief executive officers [CEO's] to induce new thinking

    in the employees at all levels.

    Many of the organization in order to fulfill their

    objectives have instituted various systems and programs.

    While constitution and implementation of systems and

    program is important, it is also necessary to critically

    examine whether these mechanisms are actually fulfilling

    objectives.

    CHAPTER SCHEME

    CHAPTER 1 Introduction and Design of Study.

    CHAPTER 2 Grasim Industries Limited - A Profile

    CHAPTER 3 World Class Manufacturing.

    CHAPTER 4 WCM Methodology

    CHAPTER 5 WCM Model

    CHAPTER 6 Implementation of WCM in Harihar Polyfibres

    Division of Grasim Industries Limited. Kumarpatnam.

    CHAPTER 7 Survey Analysis and Findings, Suggestions

    and Conclusion

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    CHAPTER - 2

    GRASIM INDUSTRIES LIMITED - A PROFILE

    HISTORY

    OTHER UNITS OF GRASIM INDUSTRIES LIMITED

    ORGANASATIONAL OBJECTIVES

    SOCIAL OBJECTIVES

    ECONOMIC OBJECTIVES

    AWARDS AND ACHIEVEMENTS

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    HISTORY

    HARIHAR POL YFIBRES, a unit of GRASIM

    INDUSTRIES L TO, is situated on the bank of river

    Tungabhadra at Kumarpatnam near Harihar in Karnataka

    state. The unit was established in the year 1972 with

    indigenous expertise, engineering and technology to

    manufacturing rayon grade pulp. Today Harihar Polyfibres

    is one of the largest rayon grade pulp manufacturers in

    India.

    Grasim Industries Ltd; Kumarpatnam, a member of

    Aditya Birla Group was incorporated on August 25,1947

    in state Madhya Bharat exactly 10 days after the country

    got independence over these years, the company has

    leading industrial conglomerate and is at present ranked

    amongst ten largest companies in Indian private sector in

    terms, turnover and profits.

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    Grasim is highly focused Industrial conglomerates

    addressing the country's need for clothing, housing and

    construction. Having fifteen division spread allover the

    country, Grasim has nine joint ventures also, out of which

    four are in India and five abroad. At Harihar, Grasim has

    two divisions namely,

    HARIHAR POL YFIBRES (PULP DIVISION) GRASILENE

    DIVISION (FIBER DIVISION)

    Harihar Polyfibres started in 1972 with a production

    Rayon Grade Pulp.

    Grasiline is a small unit started in the year 1977

    with a modest production level of 12 tons per day of

    Viscose Staple Fiber [VSF] now it has increased to 200

    tons per day of Viscose Staple Fiber [VSF].

    Grasim is the dominant VSF manufacturing with

    about 62% market share in India. Viscose Staple Fiber is

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    one of the most versatile textile industries. VSF is the

    closest man-made substitute for cotton. Due to its

    durability and cluster, its valuable property of moisture

    absorbency makes it ideal for any topical country like

    India.

    Demand for the versatile fiber has increased steadily

    over the year, largely because of its inherently superior

    characteristics as well as for the advantages of economy.

    Grasim the group flagship companies headed by son

    of late Mr. Aditya Vikram Birla Shri. Kumaramangalam

    Birla. Birla is the largest manufacturer of VSF in the

    world. Grasim is a part of the Aditya Birla Group, which

    includes its foreign interest, is the largest industrial group

    of India. This multinational conglomerate headed by Shri.

    Kumaramangalam. Birla include nearly 25 companies.

    These are located in India, Thailand, Indonesia, Malaysia

    and Egypt and operate in a wide range of product fields.

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    The Aditya Birla Group is India's second largest

    business industry with a turnover of RS.220 billion.

    A asset base of over Rs. 1.68 billion.

    A premier conglomerate of India's leading co's including

    Grasim, Hindal co, India Rayon and Indo Gulf.

    Leadership position in key business with strong

    competitive edge.

    OTHER UNITS OF GRASIM INDUSTRIES LlMITED

    Stapler Fiber Division Nagada.

    Chemical Division Nagada.

    Engineering and Development Division, Nagada.

    Weaving Division Gwalior.

    Bhiwani Textiles Bhiwani.

    Cement Division Jawad (MP).

    Vikram Ispat (sponge iron) Raigarh (Maharastra).

    Cement Division Raipur.

    Pulp Division, Mavoor-Calicut.

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    Birla Software Consultancy, Bombay.

    Birla International Marketing, Delhi.

    ORGANASATIONAL OBJECTIVES

    The term organization refers to any group of people,

    working physically together to achieve a common

    objectives. For a group to be termed as organization it has

    to fulfill two important conditions,

    Quantitative criteria

    Qualitative criteria

    Quantitative specifies that the number of persons

    should be minimum two and qualitative specifies that the

    objectives to be achieved should be common and clearly

    understood by all groups and they should be geared to

    work towards that.

    Any organization whether small or big, whether

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    domestic life or commercial enterprise has to achieve two

    types of objectives, namely social objectives and economic

    objectives.

    SOCIAL OBJECTIVES

    Social objectives refer to the reputation and image;

    the organization has got in the society. This can be termed

    as the people factor. These can be satisfied through the

    full satisfaction of the customers, suppliers, employees,

    neighboring society and government.

    Customer except a quality product at a price

    affordable and a high level of reliability of delivery

    schedule of the organization. To maintain a steady growth

    in the business through the association of suppliers with

    the organization.

    There must be continuous development through

    training development in their career and image in the

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    society by working in the organization.

    It should be pollution free atmosphere with improved

    facilities, welfare measures etc to keep the neighborhood

    clean and tidy.

    By satisfying the social needs the organization can

    build a positive image in the location where it is

    functioning.

    ECONOMIC OBJECTIVES

    Economic objective refer to the financial status of the

    organization in its effective working. This can be termed as

    productivity factor. The returns in terms of profits for the

    investments decide the economic stability of the

    organization, which is in the control of the management.

    For the basic survival and subsequent continuous

    growth of the organization, making a good profit becomes

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    an important need. Even for meeting many of the social

    obligations, the organization requires financial stability.

    By proper blending of the social and economic

    objectives, the organization must maintain a good health,

    which becomes very important need for its survival and

    growth continuously. The growth of the employees lies in

    the growth of the organization in which they are working.

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    AWARDS AND ACHIEVEMENTS

    Year Awards and Achievements

    1995Award for outstanding contribution in the field of

    labors relations by IMC, Mumbai.

    1998

    Certificate conferred on the unit of implementing

    Environmental Management system [EMS] in

    accordance with ISO 14001 standards by RU L TUV,

    Germany.

    2000The Aditya Birla Group Award for the Manufacturing

    Excellence [Bronze Medal].

    2001

    Certificate conferred on the unit of implementing

    Quality Manufacturing System in accordance with[150

    900/2000 revised standards by RUL TUV, Germany

    2001 A certificate for obtaining ISO 9001 certification.

    2001

    Certificate conferred on the unit of implementing

    Health and Safety Management System [OHSMS] in

    with OHSAS: 18001 standards by RULlUN, Germany

    2002

    Environment Protection case study ranked 2ndout of

    88 aspirants as national level by TERI and published

    in financial express of 4th April 2002.

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    2002

    Greentech Gold Award for outstanding achievement in

    the field of industrial safety by Greentech foundation,

    New Delhi

    2002The Aditya Birla Group Gold Award for Manufacturing

    Excellence and competitive advantage.

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    CHAPTER - 3

    WORLD CLASS MANUFACTURING

    INTRODUCTION

    Group Vision of Grasim

    Group Mission of Grasim

    Objectives of WCM

    WCM Policy

    WCM goals

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    INTRODUCTION

    World Class Manufacturing, a relatively new concept

    especially in the India Industrial scenario has become the

    mantra for the survival in the Industrial sector today. The

    unprecedented uncertainly accompanied with a dizzying

    rate of changes have paved way to the concept of the

    World Class Manufacturing.

    What really is WCM?

    WCM is a concept of manufacturing in which

    products conforming to the World-Class standards are

    manufactured at the last possible costs. In other words,

    WCM is a unique strategy for enterprise excellence

    through focus on manufacturing.

    Thus, WCM is an acceptable way of managing

    business to gain competitive advantage thereby ensuring

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    long-term success meeting the needs of the customers,

    employees, financial and other stakeholders and the

    community at the large.

    All these definitions reveal that WCM is a long-term

    structured approach which is cyclical [plan, do, check,

    act-PDCA] comprehensive and systemic and which

    involves cultural transformation of the people, process and

    results on a continuous basis leading to organizational

    change. Better management processes and results on a

    continuous basis leading to organizational change. Better

    management processes and organizational learning.

    WCM strives for zero loss culture coupled with high

    standards of quality and productivity. It is basically a

    team based management system relying on the,

    "Art of manufacturing for consistent excellence"

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    "Group Vision of Grasim"

    "To establish ourselves as the first choice of all

    stakeholders (as the first choice of all) including

    customers and employees in this board less world"

    "Group Mission of Grasim"

    To raise the standards of our QCDIP performance to

    the world class levels"

    Objectives of WCM

    WCM concept was developed to gain competitive

    advantage in changing and uncertain world of rapid

    technological advancement. The major objectives that the

    organization would pursue under the shade of WCM

    concept are:

    Improve the bottom line of the company.

    Building high performance teams.

    Create a congenial workplace and develop a sense of

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    ownership.

    Develop highly skilled, motivated, self-reliant

    workforce through effective training and re-training.

    Achieve zero breakdowns, zero losses and zero defects

    through continuous focused improvement.

    Ensure a clean work environment free from accidents

    and pollution.

    WCM Policy

    To achieve utmost satisfaction of our customers and

    other stakeholders through sustained excellence in all our

    activities at GRASIM, KUMARPATNAM BY

    IMPLEMENTING World Class Manufacturing program to

    deliver.

    Zero defects.

    Zero losses.

    Zero breakdowns

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    Zero pollution.

    Zero accidents.

    WCM goals

    Build high performing teams.

    Create a congenial work place and develop a sense of

    ownership.

    Develop highly skilled, motivated and self-reliant

    workforce through effective training and retraining.

    Achieve zero breakdowns, zero losses and zero defects

    through continuous focused improvement. Ensure a clean

    work environment free of accidents and pollution.

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    CHAPTER - 4

    WORLD CLASS MANUFACTURING METHODOLOGY

    Form the teams

    Equip the teams

    Visual Competition amongst the teams

    Pillars of WCM

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    Introduction

    Whether you are establishing a new business or

    transforming the existing business into a new one, it

    requires certain procedures or methodology to be followed.

    Implementation of WCM also follows a specific

    methodology to make the organization competitive for

    facing the challenges of tomorrow and for achieving the

    results. WCM methodology is based on the principles of

    Olympics. It broadly comprises of three steps:

    Form the teams

    Equip the teams and

    Visual competition amongst the teams

    Step One: Form the teams:

    The whole business is divided into small overlapping,

    cross-functional, multi skilled, self-competing high

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    performance teams covering all employees. These

    operating teams assume ownership of their QCDIP

    performance, the teams focus on the eight dimensions of

    WCM. For specific major improvements project teams are

    also formed, consisting of specialist from different

    functions, depending on the need.

    Step Two: Equip the teams:

    The teams are equipped with mindset and skills in

    using all the arms and ammunition of WCM. They are also

    trained on the rules of the game in the form of values and

    mindset for excellence. Specialized inputs are also

    provided through workshop such as JIT, SPC, PM analysis

    and other advanced problem solving techniques.

    Step Three: Visual Competition amongst the teams

    To inspire and bring the best out of the well-

    equipped team's competition is necessary. The third step

    is creating visual competition amongst the teams for

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    improving the QCDIP score. WCM strives for 100% rating

    for each team by their customers external as well as

    internal. The factory is first divided into zones with a zone

    leader assuming the ownership and responsibility of that

    area. The employees in zones are divided into teams of 5

    to 20 members; each with a team leader. Each team is

    assigned ownership of a specific area with in the zone.

    All the employees are included in over lapping

    structure and all the areas are covered in this process. A

    two-day conference cum workshop is organized to expose

    all the employees to the concepts and practices of WCM

    and to establish a common language. These educational

    programs equip all the employees with the required

    concepts, tool and techniques for implementing WCM

    systems.

    In the final step, the teams become self-motivated, all

    round quality focused and customer driven and complete

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    with one another with the killer instinct to inspire

    performance.

    Benefits through WCM

    The entire concept of WCM, adopted on a sustainable

    basis can do wonders for the organization. An organization

    can encompass the WCM program to promote excellence

    in manufacturing as a means of delighting its customers,

    employees and other stakeholders on a sustainable basis.

    These transformation programs shall lead to be

    culture, which is:Based on minimum resource

    requirements, be it equipment space or people.

    Prudent when it comes to spending money including

    buying or hireling external services.

    Highly productive with efficiency levels comparable to

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    teams take the ownership of the process and give the best

    out of them when they are inspired and through

    competition. Each team thus attempts and tries to excel in

    terms of quality and quantity cost, delivery, innovations

    and intellectual capital, productivity.

    This is an ideal work environment including

    equipment condition and operating process, which is free

    from abnormalities.

    Thus, the entire concept of WCM can be

    implemented through teams broadly classified as:-

    The enablers are those who promote exceptional

    performance from the people and the process by

    performing the following functions. Establish vision,

    mission, policies and strategies.

    Facilitate and environment conductive for learning and

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    innovation. Encourage breakthrough improvements.

    Inspire superior all round sustainable performance.

    Processes: people and process involve in the key

    manufacturing focused areas.

    The process is the means by which the organization

    harnesses and releases the talent of people to produce

    sustainable superior results.

    Success: - which are measured through the results of

    external and internal satisfaction, social satisfaction

    and business results.

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    CHAPTER - 5

    WCM MODEL

    Eight Dimensions of WCM

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    WCM MODEL

    The eight dimension of WCM are, Waste elimination

    Work environment

    JIT and stock reductions

    Equipment effectiveness / total productive maintenance.

    Customer delight - internal and external

    Quality first: SQM and best practices.

    Liaison and understanding

    Information systems, technology and cash flow.

    1. Waste Elimination

    Waste is any element of the manufacturing process

    that adds cost without adding value to the product. Waste

    not only costs money, it also extends the lead-time for

    building the product and delivering it to the customers. It

    also keeps the company from doing more productive thing

    with its resources. Wastage is a factor eating the profits of

    any organization and contributing to environmental

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    pollution.

    The competitiveness of an organization depends on

    its ability identify and weed out wasteful practices from

    across the business as "All the non value adding are

    waste". Waste / muda are usually found during.

    The time of excess production :- Excess production occur

    when companies create products or WIP for which they

    don't currently have orders, resulting in wastage of

    additional space, payment of wastages for un needed

    work, incurring more material handling cost.

    In waiting: - Resources remaining idle while waiting for

    instructions, tools, materials, power etc. is a waste and

    must be avoided.

    "Inventory is an evil":- inventory is an accumulation of

    products, WIP or materials at any stage of process. Waste

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    in inventory is often a huge source of waste in the

    organization. It ties up people, equipment, materials and

    energy that could be used for productive work.

    In conveyance: - means delay in moving components or

    products in process from one place to another or even

    people from one place to another, to get things done. Most

    operations involve series of delays. Plant layout may make

    long distance transportation necessary; they may result in

    multiple handling of parts. This can be over overcome by

    substantially simplifying the process layout by eliminating

    many stages in process as possible.

    In motion: - every motion, which is unnecessary means

    lost time. The successful approach is to try to eliminate

    the need for movement in first place. In work place,

    considerable wastage in motion can be eliminated by

    organizing the tools, materials etc.

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    In defects: - defects and processing are unnecessary and

    expensive. Defects also result in delay somewhere in the

    system and create new waste through rework. Elimination

    of defects through reliability of strengthens the process

    suppliers, materials, operation; equipment may be

    practiced for substantial reduction in defects.

    Muda also exists in communication, procedure,

    unnecessary Processing, untidiness, timing, bottlenecks

    etc.

    Waste is non-value adding activity so it becomes very

    essential to pursue a war-like approach to identify and

    eliminate waste. Thus following implementation work is

    undertaken:

    Formation of sub committee.

    Training workshop is conduced.

    Replication of workshop for all employees.

    Identification of types, of waste in respective work areas

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    linked to achieve displace in manufacturing there should

    be perfect co-ordination between these activities. Good

    house keeping and work place organization results in

    better compliances to schedules, fewer machine

    breakdowns, and low defect rates and promote exposure of

    problem areas. Besides a clean and healthy work place, it

    inspires people to give their best and fills them with pride.

    5s aims at establishing an environment, which is,

    Eliminates wastes

    Promotes wastes

    Ensures quality

    Is self-sustaining

    Improves effectiveness

    Prevent breakdowns

    Improves safety

    Makes an employee feel proud of his work place.

    A step-by-step systematic approach of 5s can be

    employed for a clean and healthy working environment on

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    a sustainable basis. The principles of 5s are as follows:

    1s Seri (sorting):- this step distinguishes necessary

    and unnecessary items and elimates the unnecessary

    ones in a systematic procedure / manner.

    2s seiton (arrangement):- step determines the type of

    storage system and lay required for easy accessibility and

    retrieval of the necessary items. The mantra of this step is

    "A place for everything and everything in its place". Usage

    of item coding and location coding along with visual

    controls makes it highly effective.

    3s sieiso (cleaning):- eliminate dirt, dust and other

    foreign matter through periodic cleaning of work place. It

    prevents accidents and unexpected failure of equipment.

    4s seikestn (standardization) :- creating of systems

    and standards covering the entire organization so that the

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    neatness / cleaning is continuously maintained extensive

    visual controls form integral part of this step for exposing

    abnormalities.

    5s shitsuke (discipline):- ensures that everyone

    practices 5s religiously. This emphasis on creating a work

    place with good habits and self-discipline.

    The 5s principles are implemented in the

    organization by:

    Formation of sub committee.

    Training workshop conducted.

    Replication of workshop for all employees.

    Audits carried out-self-audit and top management

    audit.

    Competition amongst various teams / zones.

    Reorganization and rewards.

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    Benefits

    Workers Organization

    Work effectiveness Increased production

    efficiency

    Vital working atmosphere Reduced unnecessary stock

    Cheerful/good mood Low production cost

    Safe environment More space and storage

    area obtained

    Higher work efficiency pride Confidence and recognition

    Key performance indicators

    Savings in team's space.

    5s index.

    Monetary savings.

    3. Just in time and stock reductions:

    [supply chain management! lean manufacturing / agile

    manufacturing / quick response manufacturing].

    In today's competitive world, companies no more

    compete based on their product / process or excellence in

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    anyone function but based on the supply chain strength.

    The ability to respond with speed requires on organization

    to be flexible, adaptable, devoid of bottlenecks, simple

    systems and continuous focus on eliminating non-value

    added activities. JIT producing desires variety by keeping

    costs low quality high and lead-time minimal.

    JIT is an approach of management where there is

    focus on creating a reliable and responsive supplier -

    customer relationship throughout the supply chain. JIT

    idea is simple, produce and delivers finished goods just in

    time to be sold, sub assemblies and purchase materials

    just in time to be transformed into fabricated parts. JIT

    focuses on eliminating wastage, enhancing quality and

    cutting down scrape, a streamlined plant operations that

    raises process yield, a production line balancing approach

    and employee involvement and motivated mechanism, JIT

    approach means challenge the following :-

    Set up time

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    Batch size

    Process cycle time

    Planning system

    Material handling and

    All existing practices.

    Through time is an important indication of

    manufacturing

    Effectiveness and organizational responsiveness. JIT

    approach focuses on "time compression" to help in

    achieving throughout time reduction. The real goal can

    only be achieved when JIT is working throughout the

    length of the entire supply chain.

    Some key activities required for effective

    implementation of JIT are,

    Manufacturing cycle time: - the non-value adding

    activities significantly add to the cycle time. Identifying

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    and elimination of all the non-value adding activities

    should reduce production and delivery lead-time. the ideal

    cycle time consists entirely of value added activities.

    Application of process mapping is to identify areas that do

    not add value but add time, cot and evolve action plans to

    eliminate them.

    Single minute exchange of die / quick change over

    lame: - lots production often means large inventories and

    all the problems, wastes and costs associated with them.

    JIT manufacturing requires of process items in small lots.

    To produce economically in smaller lots, time required for

    change over must be reduced. The SMED approach gives a

    three stage for shortening set up time.

    These three stages are -

    Separate internal set-up from external set-up.

    Convert internal set-up to external set-up. Streamline all

    aspects of set-up.

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    Enhancing supplier's reliability:- the focus is on

    rationalization of suppliers to concentrate on developing

    partnership relationship with them. Mutual co-operation

    and technical assistance to suppliers helping converting

    them to reliable suppliers who can then be as good as co-

    makers systems for vendor rating and feed back give the

    transparency required to build relationships with the

    suppliers.

    Delivery management:- an integrated delivery planning

    and scheduling system, which links customer

    requirements, is necessary for the organization to be able

    to deliver without building up unnecessary inventory

    across the supply chain. Synchronized manufacturing

    based on theory of constraints is advanced production-

    scheduling technique, which focus on through put

    maximization. An effective deliver management system

    works on the pull system throughout the supply chain.

    The pull system means everywhere production is in

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    response to the actual demands from customer and not

    anticipated demands.

    Improving material flow: by optimizing the layout most

    manufacturing process contain so much waste that JIT

    can't work until improvements are made process

    improvements to eliminate waste often include changes in

    the layout. Positioning manufacturing equipment closely

    together in the order of the processing steps reduces waste

    and improves the flow in several ways placing the

    machines for each step; side-by-side eliminates much of

    the waste of conveying work-in-progress long distance.

    Improving material handling system: - while designing

    the material handling system it should be kept in mind

    that the shortest distance between two points is a straight

    line and at the same time, it should be ensured that there

    is no re-handling of materials, parts etc and warehousing

    is optimum.

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    Inventory reduction: - a selective analysis of major items

    would help arriving at the minimum levels. A time bound

    plan is necessary for decreasing the inventory level in the

    organization. As reliability increases, it may be leveraged

    by operating with lesser inventories.

    The implementation program of J IT is carried on

    by:-

    Formation of sub committee.

    Training workshop is conducted.

    Project teams are formed for various projects

    identified.

    Carryout process mapping for critical processes in

    manufacturing and outside and arrive at cycle time.

    Identify non-value adding activities and plan actions

    for elimination with targets for time compression.

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    Plan and implement supplier rationalization project

    (reduce average number of supplier / item).

    Identify items / suppliers for JIT purchase and

    implementation.

    Evolve time based inventory reduction program and

    implementation. Install appropriate production scheduling

    system that integrates customer requirements with

    manufacturing and procurement.

    Benefits:-

    Shortens the production lead-time giving earlier

    return on investment. Promotes continuous

    improvements.

    Multi-selling of employees.

    Reliable and improved supplier's management.

    Reduction in space required and material handling.

    Faster customer deliveries.

    Reduced work-in-progress and defects.

    Reduced rejections in incoming supplies and

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    inventories.

    Key indicators:-

    Inventory turnover.

    Reduction in response time.

    Number of suppliers and supplier rejects.

    Reduction in material handling, inventories and

    space required.

    4. Equipment effectiveness / total productive

    maintenance:-

    In typical industrial scenario, there are instances of

    equipment breakdowns, minor -stoppages, lengthy set-up

    and adjustment times, generation of defects etc. these in

    turn result in delayed shipment, missed production

    schedules and customer complaints. By treating machines

    as partners and taking responsibility from them, we get

    machines we can rely on and help maintain an energized

    and responsive work place. This is done through

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    collaboration between maintenance and production

    introducing the concept of self-maintenance and

    operations together on a common platform to maximize

    overall equipment effectiveness [DEE]. For achieving zero

    breakdowns and zero losses, it is very important to

    practice SM. Through SM, the intelligence and skills of the

    people who are most familiar with factory machines

    equipment operators are enlisted and through SM

    operators learn to value their machines as production

    partners, keeping them operating smoothly help in making

    the work trouble free and satisfying. The principles of

    ownership is driving force behind SM. Self-maintenance

    brings maintenance and operations together on a common

    platform to maximize overall equipment effectiveness

    [DEE]. For achieving zero breakdowns and zero losses, it

    is very important to practice SM. Through SM the

    intelligence and skills of the people who are most familiar

    with factory machines. Equipment operators are listening

    and through SM operators learn to value their machines

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    as production partners; keeping them operating smoothly

    helps in making the work trouble free and satisfying. The

    principle of ownership is driving force behind SM.

    Benefits of SM:-

    Enhanced overall equipment effectiveness.

    Sense of ownership.

    Early detection of abnormalities.

    High work efficiency and effectiveness.

    Extended life of equipment.

    Low cost of production and increased production

    efficiency.

    Safe environment and reduction in hard to access.

    Skill up gradation / multi-skill of operators.

    Key indicators:

    Number of accidents.

    Overall equipment effectiveness

    Number of breakdowns.

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    Quantity of lubricant consumption.

    5. Customer delight - internal and external:-

    The existence and survival of any business

    organization depends greatly on its customers. In the

    techno times of today when the whole world has reduced

    to a global village, it is imperative for any organization to

    continuously improve its products and services to satisfy

    the global customers. Customers today have become very

    demanding and highly aware of quality. Therefore, it is

    required to continuously measure and improve the

    customer satisfaction to the levels of customer delight and

    ecstasy. Internal customer satisfaction, delight, and a

    prerequisite to external customer delight as one cannot

    deliver quality to its external customer until and unless

    it's internal customer are willing and capable of delivering

    the quality. The key aspects of focus are:

    Understanding the customer perceptions and

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    expectations about the company and competition.

    Timely response to all customers.

    Proper market assessment

    Application of internal customer concept.

    Integration of production plan with customer delivery

    plans.

    An overall strategy for competitive advantage and

    total involvement of all employees for implementation.

    Benefits:-

    Reduction in customer complaints.

    Enhances market share and organizational image.

    Development of new markets I segments.

    Satisfied employees and delighted customers.

    Zero customer loss.

    Reduction in response time.

    Key indicators:-

    Internal and external customer satisfaction index.

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    Number of customer complaints.

    Complaint handling time.

    6. Quality first: - Strategic Quality management

    [SQM]:-

    Quality is no more viewed as the measure of

    conformity of products to a given specifications. It has

    been expanded to encompass every sphere of the

    organization and gives new opportunity for achieving

    business excellence. Thus, quality now has assumed

    strategic proportions and SQM has become an essential

    dimension.

    SQM is the process of establishment long-range

    quality goals and defining the approach to achieve them.

    SQM is a road map to ensure that customer requirements

    are fully understood and met, thus attaining customer

    satisfaction.

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    Organization pursing SQM through for approach:-

    Evolve Quality integrated manufacturing strategy: - the

    strategy provides for identifying process requiring to be

    strengthened and technique for building total quality in

    organization.

    Implement Quality systems such as ISO and their

    periodic appraisal: -

    Establish systems and procedures to comply with

    recognized standards such as ISO 9000 QS 9000 and seek

    certification.

    Create company pride awareness of total Quality: -

    employee involvement and awareness towards total quality

    and customer orientation is essential.

    Create company wide awareness of total Quality and

    customer orientation: - employee involvement and

    awareness towards total quality and customer orientation

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    is essential. Appropriate forums / programs to be set in

    place to communicate the same, including feedback

    systems and measure to resolve issues pertaining to

    internal as well as external customers.

    Promotes production process control by:-

    Identify all the critical process, tasks, key process

    inputs and outputs variables and their relationship.

    Process capability measurement and analysis.

    Wide application to statistical techniques and tools

    in both manufacturing and non-manufacturing.

    Promote usage of basic problem solving tools and PM

    analysis to eliminate chronic defects [QUDIP - Quality and

    Quantity, cost delivery innovations and intellectual

    capital, productivity and pride].

    Application of bench marking:-

    It is an important process incorporation of best

    practice in the organization. These practices are identified

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    through bench marking studies done across the industries

    both in the domestic and international markets it prevents

    complacency by setting in motion the process of

    continuous improvement bench marking can be in

    following areas:

    Product bench marking.

    Functional/process benchmarking.

    Strategic benchmarking.

    Best practices benchmarking.

    Implementation of quality function deployment

    beginning with customer interactions their requirements

    are understood and translate into engineering,

    manufacturing and service requirements.

    Assets cost of Quality: - the cost of quality is assessed

    systematically and it leveraged for identifying

    improvements leading to reduction in the areas of

    appraisal and failure costs.

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    Quality function deployment process is utilized to

    understood and translate the voice of customer into

    manufacturing process service related requirements.

    Process mapping, identification of critical to quality

    characteristics, key process input / output variable,

    installing appropriate measurement systems application of

    statistical tools and techniques as appropriate are all

    involved in the implementations of projects.

    Benefits: -

    Improvements in the bottom line.

    Hidden capacity is realized.

    Reduction in defects, customer returns and

    complaints.

    Enhanced customer delight and yield.

    Reduction cost of quality.

    Achievement of benchmark targets.

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    8. Liaison and understanding:-

    Liaison is the co-ordination or communication

    between two entities for mutual benefit.

    In the highly competitive environment of cost

    through global area today, it is imperative for an

    organization to walk hand in hand with its stakeholders

    for its existence and growth. The new mantra today is that

    of "partnership" with all stakeholders relationships with

    the suppliers, customers, employers, community can turn

    around, weak organization into a strong one and at the

    same time provides, and much needed competitive edge.

    Equipping these teams with all around multi-skills would

    go along with in making the organization more flexible and

    adaptable to the constantly changing customer needs.

    Approach-liaison:-

    The approach would involve communication,

    exchange visits, collaborative projects, knowledge sharing

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    etc; social interaction also plays a definite role in

    improving the relation of the company with its

    stakeholders.

    Teamwork / team building:-

    Teams are mini enterprise inside the organization

    responsible for getting the work done and for delighting

    it's customers interface as well as external due to team

    work :-

    A great variety of complex problems can be tackled

    beyond the capability of one individual and one function.

    Problems are exposed to greater degree of diversified

    knowledge, skill and experience.

    Quality of decisions in a team and better than

    individual divisions. Cross-functional problems are

    easily solved through teams.

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    A healthy, conductive and productive work culture is

    formed.

    Skill development:-

    The (improving) importance and urgency of training

    for skill development arises due to,

    Multi-skills required in increasing global competition.

    Rapidly changing technological milieu of industry.

    Increased employees involvement required for solving

    major issues. Employees are assessed for their skills and

    their individuals

    Skill and competency mapping is done systematic

    training programs both on the job and in classroom

    training are arranged to build the skills and to faster

    multiple skills.

    Training evaluation is done to see the effectiveness of

    training.

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    Benefits:-

    Builds mutual trust and promotes transparency.

    Liaisons with the stakeholders help organization

    through various improvements leading to mutual benefits.

    Facilitates exchange of knowledge.

    Team orientation speeds up progress and synergy

    harness the knowledge and potential to a great extent.

    Employee satisfaction and enhanced due to multiple

    skills.

    Positive societal perception about the organization

    leads to a stronger organization in the emerging socio-

    economic scenario.

    8. Information systems. technology and cash flow:-

    Information system: - Flow of information plays a

    key role for taking various decisions in the best interest of

    the organization. The entire organizational systems,

    infrastructure are woven around information, be it day-to-

    day management or long-term planning. Information is

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    like oxygen for breathing. An organization depends on its

    stakeholders each one of who have their information

    needs.

    Organization requires systems to manage the various

    processes. The systems have to be effective, flexible, quick

    and easy to understand and perform and devoid of longest

    procedures systems perspective in an organization is

    essential for achieving performance excellence. The

    systems provide overall alignment of the entire

    organization with it is the whole business as well as its

    functions effectively to achieve overall performance.

    Information without systems to analyze and improve is not

    supported with the right information at the right time

    organizations have collapsed due to inadequate

    information. The IT has made gathering, processing and

    providing information easier and online, organizations

    have therefore leveraged IT for enhancing their MIS

    process controls and strengthening their systems.

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    Technology:-

    The world has witnessed rapid change in the

    technology in the recent years. While one has been talking

    about technological obsolescence for long the real meaning

    is drawing now. While certain fields such as computers,

    telecommunication, entertainment, electronics, and

    medical fields have shown for more changes, all other

    industries and businesses have been influenced

    considerably.

    The recent emergence of internet has suddenly made

    the entire business revolve against new strategies. Remote

    processing has become a reality virtual organization,

    team's office, committees have become reality. Technology

    has spared no field. Automation is seen everywhere, be it

    machinery or simple banking operation.

    In protected economies, organizations enjoyed

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    certain amount of shield from technological obsolescence.

    In the global economy, such protections are no more

    available; one has to compete with world class

    organizations that have leading edge technologies in all

    parts of the business mighty organizations have collapsed

    simply Because they did not keep pace with technology

    even in organizations. Where new technology has been

    introduced poor or slow absorption has caused collapsed.

    Implementing new technology always met with resistance

    from management because of high investment, from

    employees because of retrenchment or simply a resistance

    to change.

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    CHAPTER 6

    IMPLEMENTATION OF WCM IN HARIHAR POLYFIBRES

    CORPORATE GUIDELINES

    GOALS OF THE TRAINING PROGRAM

    IMMEDIATE OBJECTIVE OF WCM PROGRAM

    WCM at HPF

    FUTURE FRONTIER

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    IMPLEMENTATION OF WCM IN HARIHAR POLYFIBRES

    DIVISION OF GRASIM INDUSTRIES LTD.

    KUMARPATNAM

    " The world class manufacturers always go after the

    next class of customer by making the product attractive in

    one more way".

    CORPORATE GUIDELINES:

    The corporate head office of the Aditya Birla group in

    Bombay has formulated a set of guidelines, procedures,

    tools and techniques under the world class manufacturing

    training program initiated by it. These have been

    formulated in such a way that they are best suited for

    implementation among the group companies.

    The WCM training program encompasses the intent

    and elements of the initiatives that are currently being

    implemented by successful global players worldwide,

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    under the label, total product maintenance, total quality

    maintenance, or total quality control, business /

    organization, management, process re-engineering, good

    manufacturing practices, quality circles, learning

    organization, ISO 9000/14000 etc.

    GOALS OF THE TRAINING PROGRAM:

    WCM training program by the Aditya Birla Group is

    designed to improve and motivate healthy competitive

    environment with the group units and prepare them for

    tomorrows competitive challenges from global buyers.

    Ensure the elimination of non-value adding activities

    And wastage. It also puts in place a program for

    continuous improvement through combination of best of

    Japanese, American and European practices.

    Stimulate and assist organizations to participate in

    Improvement activities towards achieving total

    quality by compliance to best practices in quality

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    management systems.

    Ensure an approach that covers all areas, all

    employees at all

    Levels for quality in products, process and result

    leading to stockholders satisfaction.

    Achieve zero breakdowns, zero losses, zero defects,

    and zero Accidents and zero pollution.

    Develop a culture, which is market driven, always

    exceeding customer satisfaction.

    Immediate objective of WCM program:

    The above

    Mentioned goals can be achieved only by changing

    the mindset of the employees. They are the people who

    need to motivate by installing in them an urge to give their

    best plants to the organization.

    Hence, every employee should;

    Understand the best standards in different areas of

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    work place.

    Be committed to implementing such standards to be

    at the work place. Instantly notice deviation from

    standards.

    Reject deviations from standards; also know as

    abnormalities.

    Likes to establish the "root cause" of non-

    conformance to standards. Be keen to eliminate the

    source of deviation at the root.

    Take pride in resorting and maintaining the original

    standards. Innovative improvements on original

    standards.

    Care for the customer "external and internal".

    Refuse to accept non-value-adding activities.

    People work on process and the people wish the

    above mindset created a positive impact on quality, cost

    and delivery (QCD) triangle. Improves quality reduce cost

    and on time delivery.

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    WCM at HPF:

    WCM cell was constituted at Harihar Polyfibers in

    July 1997 with three full time members in secretariat. The

    members are all qualifies engineers. It is a stipulated

    norm that all the members of the WCM secretariat have to

    be engineers.

    Together the trios have initiated a WCM program,

    which is well suited to a process industry like Harihar

    Polyfibres, Ku marpatnam.

    Harihar polyfibres consists of around 1600

    employees. Achieving world class manufacturing

    standards takes time and it is a gradual phenomenon. At

    HPF, the install phase consists of creating awareness

    among the employees about the need for such a program

    conducting the WCM conference cum workshops creates

    this awareness.

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    WCM conference cum workshops are held for

    establishing common WCM language and identifying

    abnormalities in the plant involving all employees present

    in the conference.

    Future Frontier:-

    Thereafter in a meeting with his executives,

    managers and officers, Sri S.S.Maru said "The Gold Award

    was the result of total, collective and dedicated effort on

    part of each and every employee"- and that was saying it

    all - and at the same time he reminded "now it is time for

    us to prepare ourselves to challenge the Platinum Award

    during 2004" and that is - working together for a better,

    bright and prosperous further, at Harihar Polyfibres and

    Grasiline, at Harihar, as always.

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    CHAPTER 7

    SURVEY ANALYSIS AND FINDINGS, SUGGESTIONS

    AND CONCLUSION

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    SURVEY ANALYSIS AND INTERPRETATION

    Review of WCM program at Harihar Polyfibres

    division:-

    The review of WCM Elimate seeks to elicit the

    perceptions of the people and have reflects their feeling

    and attitudes towards the WCM program. This may be

    used to set right the weakness and capitalize on the

    strengths.

    In order to know the reactions of the management,

    staff and the workers towards the WCM program

    questionnaire survey with selected individuals was done

    during the study.

    The result obtained on the questionnaire survey is

    given below-

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    SURVEY ANALYSIS

    7.7 Table showing effective implementation and

    practices of WCM :

    Here the researcher tries to find out weather the

    WCM implementation and practices are effective

    Strongly gree Disagree Strongly Totalree disa ree8 6 4 0 18

    44 33 23 0 100

    INTERPRETATION:

    From the above table it can analyzed that 44% of the

    respondents strongly agree, 33% employees agree, 22%

    disagree and 0% strongly disagree that the effective

    implementation and practices of WCM in HARIHAR

    POLYFIBRES.

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    Graph showing effective implementation and practices

    of WCM

    Agree

    Strongly

    45%

    Agree33%

    Disagree

    22%

    disagree

    Strongly

    0%

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    7.7 WCM policy, goals and objectives

    Here the researcher tries to find out weather the

    WCM policy, goals and objectives are well know to all

    employees.

    Strongly gree Disagree Strongly Totalree disa ree

    11 7 0 0 1861 39 0 0 100

    INTERPRETATION:

    From the above observation, we can analyze that 61

    % strongly agree and 39% agree that WCM policy, goals

    and objectives that are displayed are know to employees.

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    Graph showing WCM policy, goals and objectives

    11

    7

    0 0

    0

    2

    4

    6

    8

    10

    12

    Agree disagree

    Strongly Agree Disagree Strongly

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    7.7 Roles and responsibilities as team members

    Here the researcher tries to find out weather roles

    and responsibilities as a team members.

    Strongly gree Disagree Strongly Totalree disa ree7 10 1 0 18

    39 55 6 0 100

    INTERPRETATION:

    From the above table .it can be analyzed that 39%

    strongly agree, 55% agree and 60% disagree that roles and

    responsibilities as team members are inspired to work in

    teams.

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    Graph showing Roles and responsibilities as team

    members

    7

    10

    1

    0

    0

    1

    2

    3

    4

    5

    6

    7

    8

    9

    10

    Agree disagree

    Strongly Agree Disagree Strongly

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    7.7 WCM approach applies to every industrial activity

    Here the researcher tries to find out weather WCM

    approach applies to every industrial activity.

    Strongly g ree Disagree Strongly Totalree disaaree9 9 0 0 18

    50 50 0 0 100

    INTERPRETATION:

    On the analysis of above obtained data, 50% agree to

    the point and 50% strongly agree that WCM approach

    applies to every industrial activity.

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    Graph showing WCM approach applies to every

    industrial activity

    9 9

    0 0

    0

    1

    2

    3

    4

    5

    6

    7

    8

    9

    Agree disaaree

    Strongly Ag ree Disagree Strongly

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    7.7 Kaizen is being implemented in day-to-day

    working

    Here the researcher tries to find out weather Kaizen

    is being implemented in day-to-day working.

    Strongly gree Disagree Strongly Totalree disa ree7 10 0 1 18

    39 56 0 5 100

    INTERPRETATION:

    From the analysis of the above data it can be

    interpreted that 39% strongly agree, 56% agree and 50/0

    strongly disagree that kaizen is being implemented in day-

    to-day working.

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    Graph showing Kaizen is being implemented in day-to-

    day working

    Agree

    Strongly

    39%

    Agree

    55%

    Disagree

    0%

    disagree

    Strongly

    6%

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    7.6 Communication system prevailed in the

    organization

    Here the researcher tries to find out the

    communication system prevalent in the organization.

    Communication

    Communication

    Communication

    Communication

    100 80 60 40 Total1 12 5 0 18

    50 67 28 0 100

    INTERPRETATION:

    On the observation of above table and data it is clear

    that majority of respondents i.e. 67% supported to 80%,

    28% of employees supported to 100% that communication

    system prevalent in the organization.

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    Graph showing Communication system prevailed in

    the organization

    Communication

    36%

    Communication

    29%

    Communication

    21%

    Communication

    14%

    Communication Communication Communication Communication

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    7.7 Adequate opportunities to enhance my skills

    through training

    Here the researcher tries to find out that adequate

    opportunity to enhance my skills through training.

    Strongly gree Disagree Strongly Totalree disa ree4 14 0 0 18

    22 78 0 0 100

    INTERPRETATION:

    From the above data 22% of employees strongly

    agree and 780/0 of employees agree that unit gives them

    adequate opportunities to enhance my skills through

    training.

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    Graph showing Adequate opportunities to enhance my

    skills through training

    4

    14

    0 0

    0

    2

    4

    6

    8

    10

    12

    14

    Agree disagree

    Strongly Agree Disagree Strongly

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    7.8 WCM helps to achieve six-sigma level in all

    activities

    Here the researcher tries to find out that WCM helps

    to achieve six sigma level in all activities.

    Strongly gree Disagree Strongly Totalree disa ree6 11 0 1 18

    330 0 61 0 6 100

    INTERPRETATION:

    From the observation of above data, it can be

    analyzed that, 33% of employees strongly agree, 61 % of

    employees agree and rest 60/0 of employees strongly

    disagree.

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    Graph showing WCM helps to achieve six-sigma level

    in all activities

    33%

    61%

    0% 6%

    Strongly Agree Agree Disagree Strongly disagree

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    7.9 WCM has helped in achieving:

    Here the researcher tries to find out that WCM has

    helped in achieving.

    System and standardization 13 72%

    Cleanliness 9 50%

    Reduction in accidents 7 39%

    Reduction in down time of equipment 6

    33Reduction in customer complaints 8

    44

    Reduction in pollution levels 5 28%

    INTERPRETATION:

    On the observation of above table and data 72% of

    employees agree that WCM helped in achieving system

    and standardization, 50% of employees cleanliness, 39%

    of employees reduction in accidents, 33% of employees

    agree that reduction in down time of equipment, 44% of

    employees agree that reduction in customer complaints

    and 28% reduction in pollution levels.

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    CHAPTER 8

    FINDINGS AND SUGGESTIONS AND CONCLUSION

    SURVEY FINDINGS

    SUGGESTIONS

    CONCLUSION

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    FINDINGS AND SUGGESTIONS

    SURVEY FINDINGS:

    The study consists of analysis about WCM AT HARI

    HAR POL YFIBRES. For this purpose of the study of 18

    employees were selected and their views are solicited on

    different parameters.

    1.Out of 18 employees, 8 employees strongly agree, 6

    agree and 4 disagree that Effective Implementation And

    practices Of WCM.

    (Table - 1)

    2.Out of 18 employees, 11 employees strongly agree, 7

    agree that WCM Policy, Goals and Objectives that are

    displayed are known to me.

    (Table - 2)

    3.7 employees strongly agree, 10 agree, 1 disagree that

    Roles And Responsibility AS team Members.

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    (Table - 3)

    4.9 employees strongly agree, 9 agree that WCM approach

    applies. To Every Industrial Activity.

    (Table - 4)

    5.7 employees strongly agree, 10 agree, 1 strongly

    disagree that the Kaizen Is Being Implemented In Day-

    To-Day working.

    (Table - 5)

    6.1 employee supported to 100%, 12 employee supported

    to 80%, 5 employees supported to 60% that

    Communication System Prevalent in the Organization.

    (Table - 6)

    7.4 employee strongly agreed and 14 employee agree to

    the point that Adequate Opportunities To Enhance My

    Skill through

    Training.

    (Table - 7)

    8.6 employees strongly agree, 11 of employees agree and

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    1 employee strongly disagree that WCM Helps in

    Achieving SixSigma Level in All Activities.

    (Table - 8)

    9.I have analyzed the WCM, which has helped in

    achieving System and Standardization, Cleanliness,

    Reduction in down Time Equipment, Reduction in

    Customer Complaints and Reduction in Pollution

    Levels.

    SUGGESTIONS

    1.Employee exchange program between sister concern

    should be increased so that the experiences, views and

    ideas of people involved can be shared.

    2.WCM auditing should be done by an independent and

    recognized agency and at regular intervals to improve

    its authenticity and effectiveness.

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    3.WCM training programs should be geared to support

    the corporate objectives.

    4.It is not necessary that the techniques that worked in

    one plant have to work in another. Therefore, it is

    different method of training program be formulated

    such that it~ suits the industry.

    5.Workers participation should be welcomed by the

    management concerning WCM training program.

    6.The existing forms of WCM teams should take various

    alternatives of elimination abnormality and select the

    best-suited one.

    CONCLUSION

    The information collected regarding WCM is

    effectively implemented by organizing teams and different

    committees are formed for effective practices and control

    over the teams, which is organized. Thus, through the

    effective implementation they already achieved "Gold

    Award for WCM in 2002" and compared to past they are

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    able to better and striving for the best. They are still

    striving for excellence in standardization by implementing

    six-sigma approach and they are preparing plans for

    introducing six-sigma approach in production.

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    ANNEXURE

    Questionnaire

    Bibliography

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    QUESTIONNAIRE

    Dear Sir,

    I am a final B.B.M. student from SAHYADRY ARTS &

    COMMERCE COLLEGE SHIMOGA. As a partial

    requirement of B.B.M. course. I am doing a project on

    "THE EFFECTIVE IMPLEMENTATION AND PRACTISES OF

    WCM" with special reference to Harihar Polyfibres. Hence,

    I request you to fill the following questionnaire. The

    information given by you will be used only for my

    academic purpose and will be kept confidential.

    Thanking you,

    Yours sincerely,

    (SUDHANVA B.S GOWDA)

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    Profile of respondents

    Name :

    Age :

    Department :

    Designation :

    Experience :

    1.Is WCM is effective implementation and practiced at

    HPF?

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

    2.WCM policy, goals and objectives which are displayed

    are know to me

    Strongly Agree [ ]

    Agree [ ]

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    Disagree [ ]

    Strongly disagree [ ]

    3.Roles and responsibilities as team members will be

    inspired him to work in teams:

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

    4.WCM approach applies to every industrial activity:

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

    5.Kaizen is being implemented in day to day working:

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

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    6.Communication system prevalent in the Organization

    and is effective to the extent of _

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

    7.Unit gives me adequate opportunities to enhance my

    skills through training:

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

    8.Approach of WCM helps to achieve six-sigma level in all

    activity:

    Strongly Agree [ ]

    Agree [ ]

    Disagree [ ]

    Strongly disagree [ ]

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    9.WCM has helped in achieving

    System and standardization [ ]

    Cleanliness [ ]

    Reduction of accidents [ ]

    Reduction in downtime of equipments [ ]

    Reduction in customer complaints [ ]

    Reduction in pollution levels [ ]

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    Bibliography

    Word class manufacturing: The Next Decade

    - Richard J Schonberger.

    Word class manufacturing: The lession of simplicity

    applied

    - Richard J Schonberger.

    Publisher

    Harpercollins

    Tyndale house

    Website : www.adityabirla.com