This Masterclass gives a comprehensive overview of the different models used to describe and analyse a manufacturing system. The primary purpose is to give practical models to work towards a productive and cost-efficient manufacturing system that creates a minimum load on the environment.

Manufacturing Excellence is the execution of the business strategy more consistently and reliably than your competition. Manufacturing Excellence is evidenced by results. Given two companies with the same strategy, the company with best Manufacturing Excellence will deliver faster, have lower operational risk, lower operating costs, more sustainable quality and yield and increased revenues and profits relative to its competitors, creating value for customers and shareholders.


Manufacturing Excellence is neither a specific management philosophy nor a specific methodology; it integrates those, enabling to reach highest excellence. Most of its drivers are based on continuous improvement methodologies, such as Lean Thinking, Six Sigma, QRM modelling and Machining Optimisaton Strategy (MOS) concepts. Manufacturing Excellence is based on and integrates machining process reliability; manufacturing system organization, flow and rhythm; and knowledge, skill and leadership development of the employees.

For a business leader, it is important to have insights into the key indicators or drivers regarding Manufacturing Excellence and the efficiency of his production organisation.



This Masterclass focuses on managing directors, operations managers, heads of production, plant managers, manufacturing managers, engineering managers, senior engineers etc. who want to understand, control and work with all the elements and key indicators that are defining and guiding a cost and time efficient; and sustainable operation that delivers well on customer expectations.

Introduction to NEXT STEP production concept

  • HMLV type production, challenges and solutions
  • Industry4.0 and NEXT STEP concept
  • Visible and hidden elements and variables in a production system

Resource efficient manufacturing system and machining process

  • Cost efficiency, time efficiency and energy efficiency, definition and overview of measuring and analysing tools, like e.g. OEE, TLCA, COSA …
  • Group technology
  • Standardisation and rationalisation
  • Sustainable pricing and total lead time definition

People in a machining environment

  • Role and mission
  • Knowledge and skills
  • Mindset and motivation, leadership

Reliable and controllable machining as physical process

  • Machinability models for different workpiece materials
  • Models for cutting forces, thermal analysis of a machining operation
  • Tool deterioration and tool life
  • Best practices for practical cutting process technological optimisation

Total production economics

  • Definition of the global cost equation including all variables
  • 5 key elements: costs, productivity, quality, yield and sustainability
  • CPR factors, how to use

Full background information and reference can be found in the books Knowledge, Skills and Insight makes sustainable Machining; Applied Metal Cutting Physics, Best Practice; Global Tool Deterioration, Best Practice and other STEP technical publications.