"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

FINDINGS AND SUGGESTIONS AND CONCLUSION

ANNEXURE

Questionnaire

Bibliography

CHAPTER 1

INTRODUCTION AND DESIGN

INTRODUCTION

SCOPE OF THE STUDY

OBJECTIVES OF THE STUDY

METHODOLOGY OF THE STUDY

LIMITATIONS

STATEMENT OF PROBLEM

CHAPTER SCHEME

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.

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.

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.

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

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.

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

unified

theory

compromising principles, methods, tools and system that

are applicable to all the manufacturing units. It enables

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

CHAPTER - 2
GRASIM INDUSTRIES LIMITED - A PROFILE

HISTORY

OTHER UNITS OF GRASIM INDUSTRIES LIMITED

ORGANASATIONAL OBJECTIVES

SOCIAL OBJECTIVES

ECONOMIC OBJECTIVES

AWARDS AND ACHIEVEMENTS

10

HISTORY

HARIHAR

POL

YFIBRES,

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.

11

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

12

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.

13

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.

14

Birla Software Consultancy, Bombay.

Birla International Marketing, Delhi.

ORGANASATIONAL OBJECTIVES

The term organization refers to any group of people,

working

physically

together

to

achieve

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

15

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

16

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

17

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.

18

AWARDS AND ACHIEVEMENTS

Year
1995

Awards and Achievements

Award for outstanding contribution in the field of
labors relations by IMC, Mumbai.
Certificate conferred on the unit of implementing

1998

Environmental Management system [EMS] in

accordance with ISO 14001 standards by RU L TUV,
Germany.

2000

The Aditya Birla Group Award for the Manufacturing

Excellence [Bronze Medal].
Certificate conferred on the unit of implementing

2001

Quality Manufacturing System in accordance with[150

900/2000 revised standards by RUL TUV, Germany

2001

A certificate for obtaining ISO 9001 certification.

Certificate conferred on the unit of implementing

2001

Health and Safety Management System [OHSMS] in

with OHSAS: 18001 standards by RULlUN, Germany
Environment Protection case study ranked 2nd out of

2002

88 aspirants as national level by TERI and published

in financial express of 4th April 2002.

19

Greentech Gold Award for outstanding achievement in

2002

the field of industrial safety by Greentech foundation,

New Delhi

2002

The Aditya Birla Group Gold Award for Manufacturing

Excellence and competitive advantage.

20

CHAPTER - 3
WORLD CLASS MANUFACTURING

INTRODUCTION

Group Vision of Grasim

Group Mission of Grasim

Objectives of WCM

WCM Policy

WCM goals

21

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

22

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"

23

"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

24

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

25

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.

26

CHAPTER - 4
WORLD CLASS MANUFACTURING METHODOLOGY

Form the teams

Equip the teams

Visual Competition amongst the teams

Pillars of WCM

27

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

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,

28

self-competing

high

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 wellequipped team's competition is necessary. The third step
is creating visual competition amongst the teams for

29

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

30

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

31

the world standards.

Devoid of waste in any form.

Geared towards achieving "zero breakdowns, zero

losses, zero defects and zero accidents".

Market
expectations.

driven

Innovative

always
in

exceeding

terms

of

customer

products

and

processes.

The pride of its employees and vendors.

Pillars of WCM

"The WCM approach is not a program it is the art of

managing through teams and achieving transformation
whenever needed".

Team based management systems are effective,

32

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

33

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.

34

CHAPTER - 5
WCM MODEL

Eight Dimensions of WCM

35

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

36

to

environmental

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

37

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.

38

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

39

and elimination through structured system.

Benefits through waste elimination

Savings in resources such as people, machine hour's
space, materials. Savings in energy, water, power etc.

Elimination of unnecessary paper work / duplicate

process. Reduction in inventory, rework, reprocessing and
rejections. Reduction in searching / waiting.

Key performance indicators

Percentage of waste identified / eliminated.
Savings achieved through waste elimination

2. Work environment
Work environment / 5s stands for good house
keeping concept which is the basis for continuous
improvement vital for organization effectiveness. As good
hose keeping and work place organization are directly

40

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

41

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

42

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.

43

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

44

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

45

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

46

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.

47

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 comakers 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 productionscheduling 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

48

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.

49

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.

50

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

51

incoming

supplies

and

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.

52

This

is

done

through

collaboration
introducing

between
the

maintenance

concept

of

and

production

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

53

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.

54

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

55

perceptions

and

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.

56

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.

57

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

58

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

59

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.

60

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

complaints.
Enhanced customer delight and yield.
Reduction cost of quality.
Achievement of benchmark targets.

61

returns

and

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

62

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.

63

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.

64

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 socioeconomic 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-today management or long-term planning. Information is

65

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

systems

provide

overall

performance
alignment

excellence.
of

the

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.

66

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,

67

organizations

enjoyed

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.

68

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

69

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,

70

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
quality

by

activities

compliance

to

towards

achieving

best practices

71

total

in quality

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

72

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.

73

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
employees.

polyfibres
Achieving

consists
world

of

class

around

1600

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.

74

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

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.

75

CHAPTER 7

SURVEY ANALYSIS AND FINDINGS, SUGGESTIONS

AND CONCLUSION

76

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-

77

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
Agree
8
44%

Agree

Disagree

6
33%

4
23%

Strongly
disagree
0
0%

Total
18
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.

78

Graph showing effective implementation and practices

of WCM

Disagree
22%

disagree
Strongly
0%
Agree
Strongly
45%

Agree
33%

79

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
Agree
11
61%

Agree

Disagree

7
39%

0
0%

Strongly
disagree
0
0%

Total
18
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.

80

Graph showing WCM policy, goals and objectives

12

11

10

2
0

0
Agree
Strongly

disagree
Agree

Disagree

81

Strongly

7.7 Roles and responsibilities as team members

Here the researcher tries to find out weather roles
and responsibilities as a team members.

Strongly
Agree
7
39%

Agree

Disagree

10
55%

1
6%

Strongly
disagree
0
0%

Total
18
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.

82

Graph showing Roles and responsibilities as team

members

10
10
9
8

7
6
5
4
3
2

0
Agree
Strongly

disagree
Agree

Disagree

83

Strongly

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
Agree
9
50%

Ag ree

Disagree

9
50%

0
0%

Strongly
disaaree
0
0%

Total
18
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.

84

Graph showing WCM approach applies to every

industrial activity

8
7
6
5
4
3
2
1

0
Agree
Strongly

disaaree
Ag ree

Disagree

85

Strongly

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
Agree
7
39%

Agree

Disagree

10
56%

0
0

Strongly
disagree
1
5%

Total
18
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 dayto-day working.

86

Graph showing Kaizen is being implemented in day-today working

disagree
Strongly
6%
Disagree
0%

Agree
Strongly
39%

Agree
55%

87

7.6

Communication

system

prevailed

in

the

out

the

organization
Here

the

researcher

tries

to

find

communication system prevalent in the organization.

Communic Communic Communic Communic

ation

ation

ation

ation

100%
1
50%

80%
12
67%

60%
5
28%

40%
0
0

Total
18
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.

88

Graph showing Communication system prevailed in

the organization

Communication
14%
Communication
36%

Communication
21%

Communication

Communication
29%
Communication
Communication

89

Communication

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
Agree
4
22%

Agree

Disagree

14
78%

0
0

Strongly
disagree
0
0

Total
18
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.

90

Graph showing Adequate opportunities to enhance my

skills through training

14
14
12
10
8
6
4
4
2
0

0
Agree
Strongly

disagree
Agree

Disagree

91

Strongly

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
Agree
6
330/0

Agree

Disagree

11
61%

0
0%

Strongly
disagree
1
6%

Total
18
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.

92

Graph showing WCM helps to achieve six-sigma level

in all activities

0%

6%
33%

61%

Strongly Agree

Agree

93

Disagree

Strongly disagree

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

50%

Reduction in accidents

39%

Reduction in down time of equipment

Reduction in customer complaints

33%

Reduction in pollution levels

44%
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.

94

CHAPTER 8

FINDINGS AND SUGGESTIONS AND CONCLUSION

SURVEY FINDINGS

SUGGESTIONS

CONCLUSION

95

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.

96

(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 DayTo-Day working.
(Table - 5)
6. 1 employee supported to 100%, 12 employee supported
to

80%,

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

97

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.

98

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

99

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.

100

ANNEXURE

Questionnaire

Bibliography

101

QUESTIONNAIRE
Dear Sir,
I am a final B.B.M. student from SAHYADRY ARTS &
COMMERCE

COLLEGE

SHIMOGA.

As

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)

102

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

[ ]

103

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

[ ]

104

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

[ ]

105

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

[ ]

106

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

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