Top Shops Executive Summary

2013

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Executive Summary Top SHopS oTHer SHopS ALL SHopS 5S workplace organization 58.1% 34.6% 36.4% Agile manufacturing 9.7% 5.1% 5.5% SHoPflooR PRACTICES & PERfoRMAnCES Which of the following improvement methodologies does your business use? Benchmarking 45.2% 19.7% 21.7% Cellular manufacturing 38.7% 24.6% 25.7% Continuous-improvement program 77.4% 45.4% 47.9% Just-in-time (JIT) movement of material 51.6% 25.7% 27.7% Kaizen events/blitzes 29.0% 16.2% 17.2% Kanban and pull systems 45.2% 24.1% 25.7% Overall Equipment Effectiveness (OEE) monitoring and analysis 9.7% 8.6% 8.7% Poka yoke (error prevention) 32.3% 14.1% 15.5% Quality certifcations (e.g. ISO, NADCAP, etc.) 51.6% 33.2% 34.7% Single-minute exchange of dies (SMED) 9.7% 4.3% 4.7% Six sigma 19.4% 15.1% 15.5% Theory of constraints 16.1% 8.4% 9.0% Total productive maintenance 16.1% 12.4% 12.7% Total quality management 32.3% 22.4% 23.2% Value-stream mapping 35.5% 15.9% 17.5% Other 0.0% 2.4% 2.2% No formal methodology 12.9% 18.6% 18.2% Please provide the following measures for your business in 2012: order lead time (receipt of order to delivery to customer in days) Median 17.5 21.0 21.0 Average 21.7 35.5 33.8 80th Percentile 34.0 45.0 45.0 20th Percentile 6.2 10.0 10.0 Machining-time percentage (% of order lead time that the product is being machined) Median 50.0% 25.0% 30.0% Average 56.6% 34.8% 37.5% 80th Percentile 80.0% 60.0% 65.0% 20th Percentile 36.0% 10.0% 10.0% Set-up time (minutes it takes to prepare a new job for machining — i.e., the time between the completion of the last good piece of the current run and the frst good piece of the next run) Median 60.0 60.0 77.1 137.9 130.3 80th Percentile 120.0 228.0 180.0 20th Percentile 10 52.5 Average 11.0 25.0 20.0 2013 TOP SHOPS EXECUTIVE SUMMARY mmsonline.com/topshops

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