World class manufacturing implementation in fiberglass industry: A performance analysis of operational excellence

Abstract

This study evaluates the effectiveness of World Class Manufacturing (WCM) implementation in optimizing operational performance within the fibreglass insulation manufacturing sector. The study employed a systematic approach utilising Value Stream Mapping (VSM) and Overall Equipment Effectiveness (OEE) as the primary evaluation tools. Data collection was conducted from 2023 to 2024, focusing on performance, availability, and quality metrics. Results show a significant improvement in OEE from 81.3% to 87.3%, validating the effectiveness of WCM in optimizing operations. The implementation fostered a culture of operational excellence, as evidenced by improved process understanding and increased employee engagement in improvement initiatives. Pareto analysis revealed several inefficiencies, enabling targeted interventions in line with WCM’s “zero waste” philosophy. The methodology was found to be adaptable to existing production systems, suggesting its viability for manufacturing environments in emerging economies. This study contributes to the literature by providing empirical evidence of the effectiveness of WCM in driving systematic improvement and organizational change, particularly in industrial development in emerging economies. The findings support the role of WCM in establishing sustainable operational excellence frameworks capable of meeting global competitive challenges.

Keywords

• lean production
• operational efficiency
• performance
• optimization
• manufacturing industry
• industry 4.0
• world class manufacturing