World Class Manufacturing

Do your customers expect more from your business year on year?

Is the market place ever more competitive?

If your organisation needs to  improve business performance through manufacturing excellence, this process will help you understand and acquire new skills across the wide range of disciplines in modern manufacturing management.

Whether that be continuous processing, batch assembly mode, job shop environments or another; our supportive approach will ensure you are able to see early performance improvement in the chosen areas while our educational courses will help build internal capability to broaden and deepen the skills and knowledge of your team.

World Class Manufacturing helps you deliver the products and service your customers want; allows work to be completed more efficiently and effectively improves staff morale and your bottom line. We tailor our process to meet and improve your specific business characteristics.

Best practice is vital for employers to develop their competitive advantage. You’ll retain your most valuable staff and improve long-term business sustainability using strategic guidance and implementation methodologies.

Newfound expertise will continue to help you realise on-going improvements in your organisation by applying the principles you have learned.

Are you a World Class Manufacturer?
This booklet reveals what it takes to be World Class and what this means for New Zealand manufacturers.NB: Document formatted for screen viewing only. Contact us to request a hard copy.

INTENT Director, Ian Walsh, discusses what a World Class manufacturer looks like and the lean practices, systems and processes needed to improve competitiveness.


The World Class Manufacturing programme takes organisations through five stages to become World Class:

Stage 1 – Awareness:

What Do The Best Companies Do Well?

Leaders need to understand the concept of World Class i.e. reducing waste and making work flow by using visual management, standard work, and daily accountability for performance.  The WCM 1, 2 or 3-day simulations are highly interactive workshops which leaves participants with a clear understanding of ‘World Class.’

Stage 2 – Assessment:

How And Where Do We Start On The World Class Journey?

Becoming World Class requires first assessing the organisation’s current Operational and Manufacturing practices in the areas of Workplace organisation (5S), Visual Management, Teamwork Problem Solving and Standard Work. Current and future state process mapping then follows, but not before leaders have been trained in how best to lead and manage change in manufacturing environments.

Stage 3 – Improve Performance:

Getting Immediate Results NOW.

Loss and waste analysis and baseline data collection can identify some of the current wastes that can be reduced through planned Kaizen events; and, Value Stream Mapping is used to identify the current VSM and design the future VSM. However, these tools will not sustain performance by themselves: they need to be supported by a Daily Management System which uses visual management, problem solving and Leader Standard Work to keep the organisation focused on the key business and team performance measures.

Stage 4 – Grow Capability:

Maintaining Improvements through Skills Development.

At this stage we help the organisation to make the process and procedure changes that are vital to effective ongoing problem solving and sustaining efficient workflow. We help teams to build their skills to use tools that make work visible; clarity over their roles and responsibilities, balance workloads and create standard work.

Stage 5 – Sustainability:

Sustaining a Culture of Continuous Improvement.

In World Class organisations, all employees’ actions must remain aligned to the business strategy and the key performance measures.  We show organisations how A3 can be used to deploy strategy and involve staff in problem solving and continuous improvement activities. And we help the organisation create its own culture of, and systemic approach to, continuous improvement; or adopt an integrated and highly structured improvement methodology such as TRACC.

Our capabilities and workshops  include:

  1. Leadership and Organisational Behaviour
  2. Determining and Aligning Strategies
  3. Clarity of Vision
  4. Order winners and qualifiers
  5. Organisational Design and Structure
  6. Managing Change
  7. Strategy deployment
  8. A3 business planning
  9. Operational Performance Improvement
  10. Lean Manufacturing
  11. Waste identification and reduction
  12. Six Sigma
  13. Variation reduction
  14. Theory of Constraints
  15. De bottlenecking
  16. Kaizen
  17. Targeted improvements
  18. Leader Standard Work
  19. Set up time reduction
  20. Process flow – One piece flow
  21. Problem solving
  22. Value Stream Mapping
  23. Teamwork
  24. Visual Management and Measurement
  25. Workplace organisation – 5S
  26. Workload balancing  (Heijunka)
  27. Error prevention
  28. Total Productive Maintenance – TPM
  29. Preventative maintenance
  30. Predicative maintenance
  31. Autonomous maintenance
  32. Reliability centred maintenance
  33. Benchmarking
  34. Plant and facility design
  35. Sustaining performance
  36. Continuous improvement systems
  37. Daily management systems
  38. Mentoring
  39. Coaching
  40. Tailored Education programmes
  41. Certificate in Competitive Manufacturing (NZQA)
  42. Diploma in Competitive Manufacturing (NZQA)
  43. A3 business planning
  44. Project Management
  45. Programme Management
  46. Portfolio Management