World Class Manufacturing (WCM) - How to Implement WCM

Diego Marinho, a university professor with expertise in technology management and production engineering, explains the transformative power of WCM.

Understanding WCM:

• WCM emerged in 2006 through collaboration between European and Japanese experts, built upon ten technical and managerial pillars, aiming to instill a culture of operational excellence.
• It addresses the challenge of sustaining methodologies within companies even after the departure of key personnel by providing a robust implementation framework.

Key Principles of WCM:

• WCM emphasizes a culture of continuous improvement, wherein all employees contribute to achieving world-class production standards.
• The methodology stresses visible and transparent systems to track progress and ensure accountability throughout the organization.
• It promotes the use of standardized processes and tools, with leadership playing a crucial role in driving efficiency and reducing losses.

Direction and Implementation of WCM:

• WCM is guided by matrices prioritizing safety, quality, and productivity in all projects and initiatives.
• Implementation involves establishing safety models, identifying and addressing production losses, and prioritizing improvement efforts based on data analysis.
• The methodology's success hinges on strong leadership support, regular audits, and employee engagement across all levels of the organization.

Assessment and Evolution of WCM:

• Audits, conducted every six to twelve months, evaluate progress and adherence to WCM principles, ensuring continuous improvement.
• Auditors focus on identifying areas for enhancement, encouraging proactive measures to address inefficiencies and sustain momentum.
• WCM's evolution is marked by incremental improvements, reflected in scores across technical and managerial pillars, indicating organizational growth and maturity.

Application and Benefits of WCM:

• WCM application involves aligning objectives with organizational goals, leveraging employee expertise, and fostering a culture of innovation and collaboration.
• The methodology yields tangible benefits such as waste reduction, improved productivity, and enhanced product quality.
• It enables organizations of all sizes and industries to implement systematic approaches to identify and address operational inefficiencies. 

https://www.youtube.com/watch?v=KBDARhVyEH0&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=194

We'll know understand WCM's technical and managerial pillars.

Technical Pillars:

• There are 13 technical pillars, represented as 10 due to some being paired.
• Each technical pillar contributes to a total score of 100 points.
• Technical pillars encompass areas like maintenance, quality control, and logistics.

People Development:

• Personnel development is crucial for sustainable improvement.
• Training focuses on competencies and job-specific skills.
• Mapping competencies helps in understanding workforce capabilities.

Energy Management:

• Energy management aims to identify and reduce energy wastage.
• Sustainable energy practices are emphasized for environmental preservation.

Focused Improvement:

• The WCM framework promotes ongoing improvement efforts.
• Measurement and analysis are fundamental for identifying areas of improvement.
• Projects focus on sustainable energy practices and operational efficiency.

Managerial Pillars:

• The sequence of addressing essential pillars is not fixed but guided by cost deployment.
• Managerial pillars include management commitment, organizational efficiency, and worker motivation. 

To understand better each of the World Class Manufacturing managerial and technical pillars, with links to overviews of each one as well as other resources, check out this article:  What is WCM (World Class Manufacturing) - Pillars and Structure Overview

https://www.youtube.com/watch?v=uSkBK7Vt1NE&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=196

WCM implemented step by step within the factory

Matrices and Pillars of WCM:

• WCM implementation involves three matrices: safety, quality, and productivity.
• Each matrix focuses on the biggest losses within the factory.
• Cost deployment quantifies losses and identifies areas for improvement.

Structured Implementation:

• Organized process of tackling problems.
• Rigor in application is essential for success.
• WCM is not temporary; it's a continuous path towards excellence.

Development and Resources:

• Importance of developing skilled leaders.
• Hiring specialized consultants for successful implementation.
• WCM requires commitment and continuous improvement.
• Need for focused and organized strategies.
• Implementation requires deep knowledge and consistent application.

Training and Education in WCM:

• Importance of spreading WCM training.
• Training available for various audiences.
• Encouragement for the formation of WCM specialists.

Results of WCM:

• Pursuit of operational excellence and efficiency.
• Reduction of losses and increased productivity.
• Transformation of organizational culture towards continuous improvement.

Feedback and Evaluation:

• External feedback is crucial for progress.
• Regular audits help maintain focus and quality.
• Critical view is necessary to identify areas of opportunity.

Sustaining WCM:

• Maintenance of commitment to WCM principles.
• Constant updating of practices and methods.
• Culture of learning and continuous adaptation.

Recent developments in 2025:

• The Japan Institute of Plant Maintenance (JIPM) finally made some adjustments in 2025 to be less prescriptive and to add the pillars that were missing!  Those are Supply Chain Management, Digital Transformation, and Environmental.
  • WCM already had a "Logistics and Customer Service" pillar, which is similar to SCM.
  • WCM already had Environmental.
  • WCM didn't have Digital Transformation
• At Belt Course we had already predicted these new pillars, because we've been rolling them out in industries very successfully, and didn't want to be chasing JIPM awards, we wanted to make business impact!
  • We have been using coaching programs for these pillars for years!
  • If you'd like to learn more about Digital Transformation, for example, visit this page:  https://www.beltcourse.com/digital-transformation-intro

• Looking to customize a similar Operating System for your company?  Whether you're a Divisional, Regional, Site, Operational Excellence, CI, Department, Pillar, or Project Leader...  

  • This program in any language will help top or middle leaders realize why and how to engage all of their workforce to drive cultural change!

    • Check out the benefits and trial it at no cost, here:  https://www.beltcourse.com/operating-system-and-transformation-program  

Course Forward:

• Want to Start, re-energize, or adjust a transformation?  
• Want to learn how to deploy WCM in your organization?
• Maybe you have opportunities with the managerial pillars...
• Whether you're a Company/Divisional Leader, a Site General Manager, an Operational Excellence Leader, or a Financial Stakeholder...

• Our OpEx Champion Sponsor coaching program in your language will help you lead your organization through the process, without any false starts!

• Check out the program and a free 60-day trial here:  https://www.beltcourse.com/champion-and-sponsor-curriculum-sp

https://www.youtube.com/watch?v=mEtVIlOo6RE&list=PLyVgVZd7jUlrAwzxca3m8pzo6Z3Y1KejV&index=197