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World-Class
Benchmarking
Survey
The
purpose of the World-Class Benchmarking Survey
is to collect operating performance data from
plants across a wide range of industries, analyze
the data and share key information with survey
participants. All data is confidential and specific
company names are not divulged.
Over
3,500 manufacturing plants have used the Survey
data to:
Assess
their operating performance against that of
their competitors
Determine
what level of performance constitutes
world-class in their particular
industry
Develop
objectives to achieve industry
leadership
To
participate in our World-Class Benchmarking
Survey, please fill in the data requested
below. If you do not utilize a specific measure,
please try to calculate it. Otherwise, simply leave
it blank. In a few days, you will receive a
comparison of your plant's operating performance
with that of other plants in your industry, as
determined by SIC code. If you have any
questions as you complete the survey, please
indicate in the text box below.
We
value your privacy! Please note that all
information supplied will be treated confidentially
and specific company names will not be reported.
Participation in the World-Class Benchmarking
Survey is available only to leaders in industry.
Survey results will come to you free of charge via
email. We ask that you use a valid business email
address.
Your
name:
Email:
Job
Title:
Company:
Co.
Website:
Mailing
Address:
City:
State/Province:
Zip/Postal
Code:
Country:
Telephone:
World-Class
Benchmarking Survey
Operating
Performance Information
1.
First-pass yield
(%)
The
percentage of production made to proper
specification the first time. Example: The
production schedule calls for 12,000
units. You produce 12,000 units but
also
300
units of scrap and 600 units of rework
during the production run. The total
material used was 12,000 + 300 + 600 =
12,900. Your FPY is 12,000/12,900 =
93%.
2.
Scrap rate
(%)
Percentage
scrap produced out of
total
production.
In above example, 300/12,900 =
2.3%.
3.
Defects per million (DPM) at
customer
Number
of defects shipped to customers divided by
total units shipped times
1,000,000.
4.
Finished goods inventory
turns/year
Total
sales in units divided by average finished
goods inventory.
5.
Work-in-process (WIP) inventory turns
per year
Total
sales in units divided by average WIP
inventory.
6.
% On-time shipments in full
(OTIF)
Percentage
of shipments made on time with the
required quantity.
7.
Operating Equipment Effectiveness
(OEE)
OEE
for the bottleneck or other key process in
your operation, NOT the OEE for an entire
work cell, department or facility. (Should
include Availability, Efficiency and Rate
of Quality.)
8.
Equipment downtime
%
Percentage
unplanned
downtime
(from all sources) for the bottleneck or
other key process in your operation.
Example: Process is scheduled for 168
hours during a week, but experiences 7 hrs
of losses due to breakdowns, 3 hrs
(quality), 2 hrs (material availability),
1 hr (people availability), 1 hr (other).
Equipment downtime = (7+3+2+1+1)/168 =
8.3%.
9.
Equipment breakdown
%
Of
the total unplanned downtime above, the
percentage of time equipment is down for
unplanned maintenance/repair. In the above
example, equipment breakdown is 7 hrs of
losses out of a total of 14 =
50%.
10.
% planned work
orders
Of
the total number of work orders completed,
the percentage of planned work orders
(i.e., preventive maintenance).
11.
Training hours per employee per
year
Total
training hours per year divided by the
number of hourly employees.
12.
Annual employee absenteeism
rate
The
total number of days absent divided by the
total number of days scheduled for the
entire D/L work force.
13.
Annual employee attrition (turnover)
rate
The
number of hourly employees who leave,
retire or are discharged every year
divided by the total number of
hourly employees.
14.
Lost time
rate
Total
number of lost time days for all plant
employees times 1,000,000 divided by the
total hours worked.
15.
Cross-training
%
Percentage
of hourly employees capable of performing
at least three job
functions/skills.
16.
Suggestions implemented per
yearper
employee
Total
number of suggestions actually implemented
divided by total plant employment (hourly
and salary personnel.)
17.
% of work force in
teams
Percentage
of D/L employees who are members of
empowered or self-directed work
teams.
For
items 18-24, rather than report the actual
number, we are asking for the rate of
change over the past three years. For
example, if labor cost per unit was $1.18
three years ago and today it is $1.05,
then the rate of change is (1.05 -
1.18)/1.18 = minus
11%.Please
indicate clearly whether the change is a +
or a -.
18.
Percentage change in Hourly labor
cost per unit
19.
Percentage change in Overhead cost
per unit
20.
Percentage change in Lead
time
The
time elapsed from receipt of raw materials
to the shipment of finished products,
assuming no inventories.
21.
Percentage change in
Productivity
Units
produced per labor hour.
22.
Percentage change in Changeover
time
The
time required to completely change over
product on a key process, including
removal & installation of parts and
final adjustment. Use av average
improvement rate for all key equipment. If
you are continuous process operation using
dedicated lines, please omit.
23.
Percentage change in Operating
profit
Please
use Operating rather than Net
profit.
24.
Percentage change in Market share
(%)
Demographic
Information
25.
Age of facility (years)
26.
Size of facility (square
feet)
27.
Number of full-time hourly
employees
28.
Number of part-time hourly
employees
29.
Average operating hours per
week
(e.g.,
a 24/7 operation works 168 hrs/wk. A
Monday through Friday two-shift operation
works 80 hrs/wk.)
30.
Number of units produced per
year
31.
Number of SKUs in active
production
32.
Is there a union?
Yes No
33.
Is the facility ISO or
QS certified?
Yes No
34.
Annual sales revenue (in U.S.
dollars)
35.
Please list any questions you have about
the survey or about any of the specific
metrics
requested.
36.
Please select your
industry
GRANITE
BAY GLOBAL - 916-797-2263 - email
P.O.
Box 2514, Granite Bay, California 95746 USA
