Always Lessons To Learn: Charts

Dec. 21, 2004

Manufacturing Metrics Average, median, and "benchmark" measurements for the 1998 finalists in selected categories:
Category	Average	Median	Benchmark
Reduction in mfg. cycle time (5 yrs)	51%	47%	95%
Reduction in order-to-shipment leadtime (5 yrs)	45%	45%	90%
On-time delivery rate	96%	98%	100%
Reduction in total inventory (5 yrs)	29%	36%	62%
Reduction in WIP turns (5 yrs)	39%	41%	84%

Quality Methods Percentage of finalists that extensively use these methods:
Manual statistical process control (SPC)	68%
Computerized SPC	64%
Operators inspect own work	96%
Quality function deployment	52%
Total quality management	88%
Design of experiments	56%
Poka-yoke methods	76%
Design for quality	76%
Quality circles	48%
Employee problem-solving teams	100%
Failure mode effect analysis	68%

Competitive Profile Bottom-line measures of competitive improvement for the 1998 finalists in selected categories:
Category	Average	Median	Benchmark
Productivity improvement -- increase in value-added per employee (5 yrs)	58%	35%	325%
Productivity improvement -- increase in annual sales per employee (5 yrs)	60%	46%	346%
Manufacturing cost reductions per unit, excluding purchased-material cost (5 yrs)	35%	27%	100%
Manufacturing cost reductions per unit, including purchased-material cost (5 yrs)	22%	22%	44%
Plant-level return on assets	238%	65%	2,670%
Increase in return on assets (5 yrs)	154%	50%	876%