|
|
|
Benchmark
Your Manufacturing
Practices
Get
a FREE report comparing your facility
with others in your industry.
Click
for details
|
|
Improve
Uptime
Read
our
article
on
improving
process reliability and cut
maintenance
costs
by
30%
High
Performance
Subscribe
to the
High
Performance Free
eZine
and
get practical tools, tips and techniques
for building a world-class
operation.
|
Our
Privacy Policy
|
|
Benchmarking
Best
Manufacturing
Practices
|
|
Join
our global
client network:
AlliedSignal
Bausch & Lomb
Benjamin Moore
BF Goodrich
BP
Bristol Myers Squibb
ChevronTexaco
Colgate-Palmolive
DHL
DuPont
Electrolux
GE
Kimberly-Clark
Kraft Foods
Miller Brewing
Motorola
Nabisco
NEC
Nestle
Northrup Grumman
Ocean Spray
Owens-Corning
P&G
Rayovac
Sara Lee
Sony
TDK
Texas Instruments
Toshiba
Toyota
TRW
Unilever
US Postal Service
Yamaha
|
|
Benchmarking
is the process of comparing business
processes and performance metrics to
those of world-class companies. By
understanding your plant's performance
relative to industry best practices and
standards, you'll be in a better position
to develop improvement strategies to
improve plant competitiveness.
Granite
Bay provides cost-effective benchmarking
solutions to assist help you advance
improvement efforts. In addition to our
popular Manufacturing Best Practices
Assessment, we offer benchmarking in Lean,
Maintenance, Leadership and Multishift
Operations. Each on-site Assessment
includes a brief written report outlining
findings and recommendations to improve
performance.
You
may also participate in our online
benchmarking assessments, free of
charge.
On-Site
Benchmarking
Mfg.
Best Practices
Assessment
A
comprehensive one-week on-site evaluation
of plant operations utilizing over 50 best
practices and performance metrics. and a
comparison of results to world-class
operations. For a list of performance
factors and metrics, please refer to the
online benchmarking surveys
below. More
info.
Lean
Mfg.
Assessment
Assess
critical operations and business processes
according to Lean Enterprise principles.
Identify the sources of waste, estimate
the cost savings and profit improvement
potential with Lean and compare
performance metrics with Lean standards.
Recommend Lean training topics and tools
required to advance Lean efforts.
More
info.
|
Maintenance
Best Practices
Assessment
Evaluate
the current Maintenance system against over 30 best
practices and performance metrics. Identify gap
between current systems and world-class Maintenance
standards. Assess planned maintenance, capacity
utilization/OEE, response times, technical skills,
etc. More
info.
High-Performance
Leadership
Assessment
Evaluate
current Leadership practices and capabilities
through surveys, interviews and obversation. Focus
areas include communicating, coaching, fostering
teamwork, business management, problem-solving,
delegating, crisis management, facilitation, etc.
More
info.
24-Hour
Mgmt. Assessment
An
assessment of the 24-hour management system,
including shift scheduling practices, optimal
staffing levels, shift leadership effectiveness,
intershift communications, collaboration and
consistency. More
info.
Online
Benchmarking
Based
on our experience in plant operations worldwide,
we've identified 20 Best Manufacturing Practices
that are attributed to world-class performance in
manufacturing.
Many
companies can rate "excellent" in a few of the
practices, but to be globally competitive, plants
must be proficient in applying all or most of them
to their own operations. That is, world-class
plants must have capability in both Process
Excellence and People
Effectiveness.
Below
are the 20 Best Manufacturing Practices. We have
developed a Scorecard to help you evaluate your
current operating practices, as well as a Survey to
help you assess actual performance, using
KPIs.
FREE
Benchmarking Analysis of your current
practices
FREE
Benchmarking Analysis of your current
performance
The
20 Best Manufacturing Practices
1.
Lead Time Reduction
Focus
There
is a plant-wide objective to measure and reduce
internal lead times. Value stream analyses provide
a road map; non-value-adding steps in the
manufacturing and administrative processes are
gradually eliminated; a "pull" strategy is used
where warranted; product flow is increasing; and
the facility is producing to order rather than to
stock.
2.
Manufacturing cells (Focused
Factories)
The
facility is structured into product- or
customer-focused work areas where possible, housing
all operations to manufacture a family of products.
The focus is on speed, quality and team-level
accountability rather than internal efficiencies
and machine standards. Office operations are
similarly structured to streamline
flow.
3.
Associate
Engagement
Employees
and their leaders routinely work in partnership and
meet to discuss objectives, solve problems and
suggest and implement improvements. Plant
communication is excellent,morale and job
satisfafaction are high and the shop floor goes
"above and beyond" to achieve world-class
performance.
4.
Strategic Inventory
Reduction
Raw
material, finished goods and work-in-process
inventories are reduced as a result of strategic
improvements in work flow, waste elimination and
supply chain collaboration, rather than by
arbitrary mandate, inventory shifting or accounting
gimmicks.
5.
Cross-Functional
Teamwork
There
is a high level of teamwork and coordination
between organizational units and strong internal
customer-supplier relationships. The result is
quick action on pressing organizational issues.
Traditional interdepartmental and intershift
rivalries have been replaced by cooperation and
collaboration. Support functions act as subject
matter experts in "Centers of Excellence" to ensure
successful adoption of best
practices.
6.
Equipment/Process
Reliability
An
effective system is in place to maximize equipment
availability and efficiency. Corrective,
preventive, predictive and autonomous maintenance
practices are in place. Maintenance and Operations
work in partnership to achieve world-class levels
of Overall Equipment Effectiveness (OEE), with
operators performing a vital tasks in maintaining
equipment reliability.
7.
Quick Changeover
Quick
changeover/SMED methods are employed to increase
equipment availability and respond quickly and
economically to changing schedules and customer
needs. The goal is not to eliminate changeovers,
but to increase their
efficiency.
8.
High-Performance
Leadership
All
levels of plant leadership provide effective
coaching, training & mentoring to subordinates,
ensuring peak performance, strong teamwork and a
skilled, engaged work force. Senior management is
committed to developing highly effective leaders.
Internal communications are excellent, as rated by
the shop floor.
9.
Continuous
Improvement
Employees
are engaged in CI projects and activities on a
regular basis. All teams meet to set goals, solve
operating problems and implement corrective action.
Improvement efforts tie directly to the plant's
operating objectives.
10.
In-Process Quality
Product
quality is built-in at the operating level.
Employees have the ability and the authority to
make product quality decisions in process and
quality management tools (SPC, error-proofing,
etc.) are in place and
effective.
11.
Optimal Shift
Schedule
For
companies that operate multiple shifts, an
effective 24-hour management system provides the
necessary support around the clock. Shift schedules
are in place that meet both operational and
employee needs. The shift schedule allows for
adequate training, coverage, skills availability
and overtime minimization.
12.
Standard Operating
Procedures
The
plant is ISO (or QS) certified. Operating
procedures and quality standards are consistent
across work areas and shifts and a formalized
process is used to ensure
sustainability.
13.
Goal Deployment
Key
performance indicators and shop floor goals are in
place for each area, developed at the operating
level and tied directly to plant goals. The process
is a dynamic one that energizes and engages the
entire organization, and there is a clear "line of
sight" between individual/team effort and plant
performance.
14.
Visual Management
Systems
Plant
and team scoreboards and other visual means of
controlling and improving operations are used
throughout the plant. Operational status
information is available quickly and accurately to
anyone who needs it.
15.
Plant Safety, Loss Prevention
& Organization
Effective
training & awareness, thorough incident
investigations and a 5S/6S organization program
ensure an orderly, efficient and safe workplace.
The process is a routine part of everyone's work
function and no longer viewed as an
"add-on".
16.
Incentives, Rewards &
Recognition
There
is an effective incentive and recognition system
that promotes continuous improvement and rewards
outstanding individual, team and plant performance.
The process effectively engages the entire
organization, promotes the kind of behaviors and
activities that encourage continuous improvement
and is not viewed as an
entitlement.
17.
Problem-Solving
Capability
Employees
at all levels are effective problem-solvers and are
able to utilize Root Causes Analysis and Corrective
Action to solve many operational challenges. Such
efforts support the continuous improvement process
and have become a roujtine part of everyone's job
function.
18.
Cross-training
& Multi-skilling
Multi-skilling
in each area provides the needed flexibility to
operate efficiently and improve productivity,
quality, cost and delivery.optimize operating
performance. Training of all personnel, including
the plant leadership team, is a key
priority.
19.
Supplier
Partnerships
The
organization has collaborative, rather than
adversarial, relationships key certified suppliers
to continuously improve material cost, quality
& delivery, benefitting all parties. The
emphasis is no longer on unit pricing, but total
procurement cost, which includes pricing,
logiostics, quality and carrying
costs.
20.
World-Class Performance
Measures
A
world-class operation must have the right
performance measures in place - those that reflect
customer needs rather than internal accounting
standards. Performance metrics measure performance
against world-class standards, are generated and
controlled by shop floor personnel and are
successful in rallying the entire organization
toward higher performace
levels.
For
a Benchmarking Analysis of your current
practices,
please
click
here.
For
a Benchmarking Analysis of your current performance
using KPIs, please click
here.
|
|
