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    01.12 WCM Foundations in Saint-Gobain

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    Sathish Kumar P
    The document discusses the foundations of the World Class Manufacturing (WCM) program at Saint-Gobain, including standardization, 5S practices, visual management, focused improvement through kaizen events and teamwork, value stream mapping, and cost deployment to identify and achieve savings goals.

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    01.12 WCM Foundations in Saint-Gobain

    Uploaded by

    Sathish Kumar P
    374 views10 pages
    The document discusses the foundations of the World Class Manufacturing (WCM) program at Saint-Gobain, including standardization, 5S practices, visual management, focused improvement through kaizen events and teamwork, value stream mapping, and cost deployment to identify and achieve savings goals.

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    The document discusses the foundations of the World Class Manufacturing (WCM) program at Saint-Gobain, including standardization, 5S practices, visual management, focused improvement through kaizen events and teamwork, value stream mapping, and cost deployment to identify and achieve savings goals.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    374 views10 pages

    01.12 WCM Foundations in Saint-Gobain

    Uploaded by

    Sathish Kumar P
    The document discusses the foundations of the World Class Manufacturing (WCM) program at Saint-Gobain, including standardization, 5S practices, visual management, focused improvement through kaizen events and teamwork, value stream mapping, and cost deployment to identify and achieve savings goals.

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    © All Rights Reserved
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    WCM Foundations in Saint-Gobain

    WCM Foundations

    What’s in the Foundations of the


    WCM temple?
    WCM Foundations in Saint-Gobain

    Foundations support Pillars

    EFESO - Saint Gobain 2


    WCM Foundations in Saint-Gobain

    Standardization
    Standardization is one of the key tool of WCM program
    restored and/or defined by improvement teams
    standards sustain after Loss Prevention phase
    3 kinds of standards
    Expected Standard
     Ex: Standard duration for changeover is 35min
     5S standards
    Standard Operating Procedure (SOP)
     List of activities to be carried out in order to achieve the expected standard
     Ex: Setup tasks list, cleaning and inspection procedure…
    One Point Lesson (OPL)
     Visual illustration of one point
     Ex: Clean VS Dirty, Simple improvement…

    EFESO - Saint Gobain 3


    WCM Foundations in Saint-Gobain

    Standard duration of changeover


    Define the current best standard and train the operators
    (Example from Kolo plant)

    EFESO - Saint Gobain 4


    WCM Foundations in Saint-Gobain

    5S is continuous attitude to take care of the working place (safety and


    ergonomic conditions, lean approach to reduce waste of time for
    movements and searching)

    No restoration nor improvement activity can be started without the


    area validated in 5S. Therefore, 5S has to be considered as integrated
    in all Loss reduction routes (restore & hold the gains)

    EFESO - Saint Gobain 5


    WCM Foundations in Saint-Gobain

    Autonomous & Visual management: simplify the life in the


    plant (Reliability pillar is one of the expert)
    Visual Management of the
    Workplace

    Visual Management of the


    Machines

    War Room WCM Team Boards


    SG Sekurit SG Sekurit
    Chantereine Chantereine
    EFESO - Saint Gobain 6
    WCM Foundations in Saint-Gobain

    Focused improvement & People involvement

    Kaizen events TEAMWORK for quick improvements on focused


    Kaizen WS subject from top-down (cost deployment or VSM) and
    Quick kaizen bottom-up (people suggestions) initiatives

    Foreman, operators, supervisors (all the levels


    TEAMWORK of the organization)
    Production, Quality, Maintenance, EHS,... (all the
    functions in the organization)

    EFESO - Saint Gobain 7


    WCM Foundations in Saint-Gobain

    Time Based Management


    VSM is the 1st WCM activity of plant management team
    VSM is the vertebral column to all losses identification (7 wastes)
    Value Stream Mapping
    Steps - Single Plant

    The Customer Focus and Service Pillar team is the expert of VSM

    EFESO - Saint Gobain 8


    WCM Foundations in Saint-Gobain

    Cost deployment
    Cost deployment is the management tool used with VSM to
    define priorities and build plant Master Plan
    Loss Intelligence supports Cost Deployment for all Pillars

    • Identified losses = total Division/Plant


    losses found Ref. net sales
    100,0% 20% 8% 5% 2% 0%
    • Identified savings =
    recoverable losses (=
    total – technical limit) 20% 37% 61% 48% 19%
    Ref. to
    previous value
    • Planned savings =
    losses planned to be
    saved in a certain
    period (ie 1 year) 939.929 190.727 70.609 43.251 20.564 3.940
    Actual YTD planned Achieved YTD
    Net sales previous year Losses Identified Identified Savings Planned Savings
    • Actual ytd planned Savings Savings

    savings = ytd savings


    target (ytd= year to
    date)
    • Achieved ytd savings =
    achieved ytd savings Do we Are we aggressive Are we effective
    from Saving System
    have a vision? in target setting? in implementation?

    EFESO - Saint Gobain 9


    WCM Foundations in Saint-Gobain

    Pillars continuously reinforce the Foundations while


    Foundations continuously nurture and support
    Pillars

    Loss
    Loss
    Eradication
    Intelligence

    Loss
    Prevention

    EFESO - Saint Gobain 10

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