Issue link: https://mmstopshopsexecsummary.epubxp.com/i/147470
Executive Summary Top SHopS SHoPflooR PRACTICES & PERfoRMAnCES H ALL SHopS oTHer SHopS aving advanced machine tools and ancillary equipment does not ensure success. Top Shops excel because they work to establish effective processes around that capacity to facilitate fow and minimize waste on the shop foor. In doing so, they are able to realize higher spindle utilization (80 percent versus 65 percent in median values), faster order lead time (17.5 days versus 21 days) and a better on-time delivery rate (95 percent versus 90 percent in median values). Top Shops are also more likely to use machine monitoring and connectivity tools. This technology provides real-time process data that helps them make the proper improvements more quickly. They also do a better job of providing employees with advanced tools where needed. For instance, Top Shops are more likely to have sophisticated measurement equipment, such as CMMs and measurement arms, near production areas on the shop foor. Leading shops don't rest on their laurels, either. A signifcantly higher percentage of Top Shops have implemented a formal continuous improvement program. Those shops also employ lean manufacturing concepts, including 5S workplace organization, kaizen events and value stream mapping. In fact, the percentage of Top Shops that perform value stream mapping is twice that of other shops. Applying this concept can be challenging in a highmix/low-volume environment, but it certainly isn't impossible. A greater number of shops are integrating machine-tending robots, which isn't surprising given today's challenges of a small pool of skilled labor and growing healthcare costs. While the percentage of Top Shops using automation has remained relatively steady over the last three surveys (right around 16 percent), a much higher percentage of the other surveyed shops said they have robots (14 percent) compared to past surveys. Set-up time (minutes it take to prepare a new job for machining) 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 52.5% 60.0% 60.0% Median 77.1% 137.9% Average 130.3% 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Top Shops Other Shops All Shops on-time delivery rate (% of goods delivered on time) 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 110 120 130 140 | IMTS imts.com 95.0% 90.0% 92.0% Median 93.2% 86.6% 87.4% Average 0 10 20 30 40 50 60 70 80 90 SPONSORED BY 100 AMT amtonline.org 9