Quality Tables

Labor-Turnover Rate (%)

25th Percentile Median 75th Percentile 90th Percentile Mean
Aerospace 11.0 6.0 2.0 1.0 8.8
Automotive 15.0 6.0 3.0 1.8 12.1
Chemicals 10.0 5.0 3.0 1.0 8.1
Construction 15.0 6.0 2.7 1.0 14.5
Consumer packaged goods/nondurables 15.0 8.5 3.0 2.0 14.2
Consumer product durables 20.0 8.0 4.0 2.0 15.8
High tech 14.0 7.3 3.0 2.0 10.6
Industrial equipment and machinery 15.0 6.6 3.0 1.0 10.4
Pharmaceuticals 14.7 6.5 2.0 1.0 9.3
Printing and publishing 11.1 8.5 5.0 1.1 10.8
World-class manufacturers* 11.1 5.0 2.0 1.0 8.2
Top performers** 14.0 6.4 3.0 1.4 11.4
All 15.0 7.0 3.0 1.7 11.9
*Based on respondent self assessment **75th percentile for delivery (98% plus on time) and quality (98% plus first-pass yield) 1 Annual labor-turnover rate for the most recent fiscal year First-Pass Yield (%)
25th Percentile Median 75th Percentile 90th Percentile Mean
Aerospace 80.0 95.0 98.0 99.0 88.7
Automotive 90.0 95.0 98.0 99.0 91.3
Chemicals 90.0 95.0 98.0 99.0 91.6
Construction 90.3 95.0 98.0 99.0 91.4
Consumer packaged goods/nondurables 93.0 97.0 98.5 99.0 93.5
Consumer product durables 90.0 95.0 98.0 99.0 90.8
High tech 89.5 95.0 97.5 99.0 90.4
Industrial equipment and machinery 90.0 95.0 98.0 99.0 91.8
Pharmaceuticals 90.0 95.0 98.0 98.5 91.8
Printing and publishing 90.0 95.0 98.0 99.0 93.2
World-class manufacturers* 94.0 97.0 98.3 99.3 94.7
Top performers** 98.0 99.0 99.0 99.7 98.7
All 90.0 95.0 98.0 99.0 91.1
*Based on respondent self assessment **75th percentile for delivery (98% plus on time) and quality (98% plus first-pass yield) Finished-product first-pass yield percentage for primary products Scrap And Rework (%)
25th Percentile Median 75th Percentile 90th Percentile Mean
Aerospace 6.0 3.0 2.0 1.0 5.2
Automotive 5.0 2.0 1.0 0.4 3.4
Chemicals 5.0 2.0 1.0 0.5 4.4
Construction 5.0 2.0 1.0 0.2 3.1
Consumer packaged goods/nondurables 5.0 2.0 1.0 0.5 3.5
Consumer product durables 5.0 2.0 1.0 0.5 3.7
High tech 5.0 2.0 1.0 0.3 4.1
Industrial equipment and machinery 5.0 2.0 1.0 0.3 3.5
Pharmaceuticals 5.0 2.0 1.0 0.5 3.4
Printing and publishing 6.0 3.0 1.0 0.5 4.9
World-class manufacturers* 4.0 2.0 1.0 0.5 3.2
Top performers** 2.0 1.0 0.5 0.1 1.6
All 5.0 2.0 1.0 0.4 3.8
*Based on respondent self assessment **75th percentile for delivery (98% plus on time) and quality (98% plus first-pass yield) Scrap and rework costs as a percentage of sales Warranty Costs (%)
25th Percentile Median 75th Percentile 90th Percentile Mean
Aerospace 2.8 1.0 0.9 0.3 2.2
Automotive 2.0 1.0 0.1 0.0 2.1
Chemicals 2.0 1.0 0.5 0.0 2.4
Construction 2.0 1.0 0.5 0.0 2.0
Consumer packaged goods/nondurables 2.0 1.0 0.2 0.0 2.1
Consumer product durables 3.0 1.0 0.5 0.0 2.2
High tech 3.0 1.0 0.5 0.0 2.9
Industrial equipment and machinery 3.0 1.0 0.5 0.2 2.2
Pharmaceuticals 3.0 1.0 0.4 0.0 2.8
Printing and publishing 2.3 1.5 0.8 0.1 2.1
World-class manufacturers* 2.0 1.0 0.3 0.0 1.8
Top performers** 1.0 0.5 0.0 0.0 1.3
All 2.4 1.0 0.5 0.0 2.3
*Based on respondent self assessment **75th percentile for delivery (98% plus on time) and quality (98% plus first-pass yield) Warranty costs (repair and replacement) as a percentage of sales Implementation Of Quality Techniques (% Of Respondents)
No Implementation Some Implementation Extensive Implementation
Six Sigma quality techniques 68.4 25.1 6.5
Error proofing (e.g., poka-yoke) 55.8 36.5 7.7
Process capability measurements (e.g., Cpk) 33.0 45.8 21.2
Total quality management 24.9 53.6 21.5
Statistical process control 23.6 54.2 22.2
Formal continuous improvement program 17.8 49.1 33.1
Percentage Of All Respondents Certified
%
ISO 9000 certification 50.8
QS 9000 certification 16.8
ISO 14000 certification 5.2
No certifications 42.6
Percent ISO 9000 Certified
%
All 50.8
Top quality performers* 47.4
Poor quality performers** 51.4
No certifications 42.6
*first-pass yield 75th percentile and higher (98%) **first-pass yield 25th percentile and lower (90%)
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