Always Lessons To Learn: Charts

Manufacturing Metrics
Average, median, and "benchmark" measurements for the 1998 finalists in selected categories:
Category Average Median Benchmark
Reduction in mfg. cycle time (5 yrs) 51% 47% 95%
Reduction in order-to-shipment leadtime (5 yrs) 45% 45% 90%
On-time delivery rate 96% 98% 100%
Reduction in total inventory (5 yrs) 29% 36% 62%
Reduction in WIP turns (5 yrs) 39% 41% 84%


Quality Methods
Percentage of finalists that extensively use these methods:
Manual statistical process control (SPC) 68%
Computerized SPC 64%
Operators inspect own work 96%
Quality function deployment 52%
Total quality management 88%
Design of experiments 56%
Poka-yoke methods 76%
Design for quality 76%
Quality circles 48%
Employee problem-solving teams 100%
Failure mode effect analysis 68%


Competitive Profile
Bottom-line measures of competitive improvement for the 1998 finalists in selected categories:
Category Average Median Benchmark
Productivity improvement -- increase in value-added per employee (5 yrs) 58% 35% 325%
Productivity improvement -- increase in annual sales per employee (5 yrs) 60% 46% 346%
Manufacturing cost reductions per unit, excluding purchased-material cost (5 yrs) 35% 27% 100%
Manufacturing cost reductions per unit, including purchased-material cost (5 yrs) 22% 22% 44%
Plant-level return on assets 238% 65% 2,670%
Increase in return on assets (5 yrs) 154% 50% 876%
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