Top Shops Executive Summary


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Executive Summary 10 2015 TOP SHOPS EXECUTIVE SUMMARY The most surprising fnding from this year's survey relates to setup time, defned as the time between the completion of the last good piece of the current run and the frst good piece of the subse- quent run. This year's survey is the frst in which the benchmark- ing group has a longer median setup time than the other shops (90 minutes compared to 68 minutes). It could be that the Top Shops are machining more complex components with higher proft margins that simply take longer to set up compared to more straightforward parts. That said, a higher percentage of Top Shops use quick-change workholding devices (56 compared to 38 percent) to enable fast setups and fxturing to enable multiple workpieces to be machined in a single cycle (81 com- pared to 54 percent). Top Shops also use machine-tending robots more than other shops as well as additional forms of automation. This includes the aforementioned FMS and turning center bar feeds (44 compared to 34 percent) and bar pullers (37 compared to 21 percent). They are more likely to implement lean manufacturing practices to improve their processes, too, such as 5S workplace organization, cellular manufacturing, value stream mapping and kaizen events. Key Performance Indicator—Spindle utilization is one shopfoor metric that demonstrates the extent to which leading shops have established an effective overall approach to machining. Top Shops report a median spindle utilization of 75 percent compared to 65 percent for other shops. SHOPFLOOR PRACTICES & PERFORMANCE Top Practice—Top Shops also tend to be more focused on lean manufacturing and have cultures of continuous improvement. Related to the latter, 62 percent of these shops have developed a formal continuous improvement program compared to 46 percent of other shops. Trend—The Top Shops' use of machine-tending robots has increased in each year we've offered the survey, with nearly one- quarter of the 2015 Top Shops reporting they've integrated this type of automation into their processes compared to 11 percent in 2011 (see table below). Shopfoor Practices: Use of Machine-Tending Robots 60% 50% 40% 30% 20% 10% 0 2012 22.6% 2013 33.3% 2014 40.4% 15% 2011 2010 10.8%

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