Since 2017, OCAP manufacturing plants have adopted the World Class Manufacturing (WCM) system, a structured, strict and integrated production methodology that involves the whole organization, covering safety, environment, maintenance, logistics as well as quality.
The main target of WCM system is to keep improving all production performances in order to guarantee product quality and meet customer’s expectations. The projects developed within the WCM, which rely on a strong involvement all the employees, have as common goal the systematic reduction of losses and waste, up to the ultimate result of zero accidents, zero waste, zero failures and zero stocks.
WCM is based on the systematic reduction of all types of waste or loss, and on everyone's involvement (at all hierarchical levels of the corporate), through the rigorous application of methods and standards.
WCM is focused on building a production system where:
- The sensitivity for safety is a basic value.
- The customer's voice reaches the workshop.
- Leaders are fond of standards.
- No kind of waste and loss is accepted.
- The methods are applied with rigour and tenacity.
- All anomalies/faults are made visible.
- The involvement of people is the engine of change.
The WCM is depicted as a temple supported by 10 technical pillars (pilar).
Each pillar addresses a topic and represents a scope of action in a technical area:
- Safety – Workplace Safety
- Cost Deployment – Economic loss sources
- Focus Improvement – Improvement focused on a specific problem
- Autonomous Maintenance – Workplace Organization
- Professional Maintenence
- Quality Control
- Logistic / Customer Services
- Early Equipment Management, Early Product Management – Acquisition strategy related to the means of work / processes
- Enviroment – Environment and exploitation of energy equipment
- People Development – Development of staff skills
These technical pillars are followed by 10 managerial pillars as well. The managerial or operational pillars constitute the actions that the WCM leader or the plant manager must carry out, aimed at promoting the commitment and self-responsibility of the different personnel in charge for each individual pillar.
- OPL One Point Lesson
- SOP Standard Operating Procedure
- SMP Standard Manutentive Procedure
- 4M MAN/METHOD/MATERIAL/MACHINE method of breaking down the problem to detect sensitive areas
- 5W 5 WHY ask and iterate questions about the reason for a phenomenon
- 5W+1H WHAT/WHERE/WHEN/WHICH/WHO/HOW Position the phenomenon within these items
- 3M Objective assessment of the workplace
- KAIZEN Specific improvement projects
- KPI Key Performance Indicators – Objective result indicators
- KAI Activity indicators (see Kaizen)
WCM’s goals aim to achieve the “zero” value in different areas: defects, stocks, inefficiencies, downtime, bureaucracy, customer dissatisfaction, etc.
To reach zero, the improvement must be obviously continuous.