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Always Lessons To Learn: Charts
Dec. 21, 2004
None
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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