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Executive Summary
12 2015 TOP SHOPS EXECUTIVE SUMMARY
mmsonline.com/topshops
SHOPFLOOR PRACTICES & PERFORMANCE
Setup time (time in 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 90.0 67.5 70.0
Average 184.0 166.2 170.4
80th Percentile 180.0 216.2 180.0
20th Percentile 30.0 30.0 30.0
On-time delivery rate (% of goods delivered on time)
Median 95.0% 90.0% 92.0%
Average 92.0% 88.0% 88.9%
80th Percentile 98.0% 98.0% 98.0%
20th Percentile 85.0% 80.0% 80.0%
Finished-product frst-pass quality yield
(% of product that passes fnal inspection on frst attempt)
Median 98.0% 95.0% 95.0%
Average 94.0% 90.3% 91.3%
80th Percentile 99.0% 99.0% 99.0%
20th Percentile 95.0% 85.2% 90.0%
Scrap and rework % (cost of scrap and rework as % of shop sales)
Median 1.0% 2.0% 2.0%
Average 3.0% 4.5% 4.1%
80th Percentile 3.0% 5.0% 5.0%
20th Percentile 1.0% 1.0% 1.0%
Scrap and rework % (number of scrapped or reworked
parts as a % of total parts produced)
Median 1.0% 2.0% 2.0%
Average 2.0% 4.6% 4.1%
80th Percentile 3.0% 5.0% 5.0%
20th Percentile 1.0% 1.0% 1.0%
Machine usage (average hours machine is in production per 24-hour day)
Median 11.0 10.0 10.0
Average 13.0 10.8 11.2
80th Percentile 17.0 16.0 16.0
20th Percentile 8.0 6.0 7.0
Spindle utilization time (in-cut time as % of machine uptime)
Median 75.0% 65.0% 70.0%
Average 71.0% 57.7% 61.0%
80th Percentile 85.0% 80.0% 80.0%
20th Percentile 60.0% 30.0% 40.0%