Finished Product, First Pass Quality Yield
Best Plants competition participants are asked to submit a range of quality data, including first pass yield. IW's definition of first pass yield is the percentage of finished products that meet all quality-related specifications at a final test point. When calculating yield for components, the percentage that meets all quality-related specifications at a critical test point without being scrapped, rerun or reworked. In process industries, yield often is calculated as the percentage of output that meets target-grade specifications (excluding saleable "off-grade" product).
On-the-job training requirements vary widely among the IW Best Plants Award winners and finalists. While the data are not shown here, the IW Best Plants application also requests information about formal classroom and online training.
Average Overtime Hours Per Week, Per Employee
These data are per employee. So, for instance, the median overtime hours per week, per employee, among the 2017 IW Best Plants winners and finalists were 2.9 hours. At least one facility in that year averaged 10 hours per week of overtime, per employee.
OSHA-Reportable Incident Rates
As a whole, the IndustryWeek Best Plants winners' and finalists' safety performances compare well against their industry averages. An exception occurred in 2016, when the average and the median OSHA rates exceeded their industry averages.
Documented Costs Savings, Per Employee
The IW Best Plants applications ask participants to provide total documented cost savings as a result of specific improvement programs and projects over the most recent calendar year. For the purposes of this chart, we then divided that dollar figure by the number of employees in the manufacturing facility. (The IW judges, when reviewing applications, does not look for a specific level of cost savings. The data is requested as part of our effort to get a complete picture of continuous improvement activities within a facility.)
Supplier On-Time Delivery
No manufacturing plant is an island. Its supply chain can boost its performance or drag that performance down. Given the strong links between the two, the IW Best Plants application asks entrants a series of questions about supplier performance. This is one of those questions.
Frequency of Master Production Schedule Updating
Just how agile and flexible are your manufacturing operations? We aim to find out.
Reduction in Order-to-Shipment Leadtime
The IndustryWeek Best Plants application asks several questions to gauge the responsive of entrants' manufacturing operations -- as well as any successes in improving responsiveness. Almost without exception, IW Best Plants winners and finalists have successfully whittled down their order-to shipment leadtimes.
Percentage of Reactive Maintenance Work
How much of your maintenance work is an unexpected -- and unwelcome -- surprise? The less, the better.
Finished-Goods Inventory Levels
Many variables come into play when determining optimal levels of finished-goods inventory. The numbers vary widely among IW Best Plants winners and finalists.