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MESA Metrics to Support Major Initiatives 2007 Study

This survey on Metrics to Support Major Initiatives, performed by Industry Directions, Inc. in conjunction with MESA International, is intended to learn the degree to which manufacturers are pursuing Lean, Real-time Enterprise and Quality initiatives, what KPIs they use to track their performance in those areas, and how their metrics programs work.

It will take approximately 20 minutes to complete the questionnaire. 

If you are not pursuing one of the initiatives (Lean, Real-time Enterprise or Total Quality), please answer that question No and you may skip to the next section as noted.
 
Your participation in this study is completely voluntary. In return, you will be among the first to receive a copy of the public report of survey findings this fall. Your responses will be kept confidential and only reported in the aggregate. Nothing will be attributed to you or your organization
 
If you have questions at any time about the survey or the procedures, contact Julie Fraser at jfraser@industrydirections.com. 

Thank you very much for your time and support.

1. Please define your role in your organization.
  Plant Manager / Plant Operations IT / Production IT Line of Business / Enterprise
     
2. Which of the following best identifies your company's product/industry? Please identify one in the primary column and as many as you feel are pertinent in the secondary column.
  Primary (Select 1) Secondary (Select all that apply)
Aerospace & defense    
Apparel    
Automotive & other vehicles    
Beverage    
Chemicals    
Consumer durables & non-packaged    
Consumer Packaged Goods    
Distribution, Wholesale & Logistics    
Electronics equipment    
Fabricated metals    
Fabrication & Assembly    
Food    
Furniture    
Heavy Machinery    
Industrial Equipment    
Medical Devices    
Mill or roll products (Paper, textiles, primary metals, films, etc.)    
Oil & Gas - Petroleum    
Pharmaceutical    
Plastic products - molding, forming etc.    
Semiconductor    
Other      
3. Which of the following best describes the mix of products through your production process?
  High mix Medium Mix Low Mix Dedicated Lines
       
4. Which of the following best describes your production process?
 
Discrete  
Continuous Process  
Batch Process  
Packaging plus batch or process  
Other Mixed Mode  
Other  
5. What is the scope on which your answers are based? (select one)
  Plant Division, Region or Business Unit Enterprise
     
6. Are you pursuing “Lean as eliminating waste”? If yes, continue to next question; if no please proceed to question 12.
  Yes Not Yet; Plan to No
     
7. Which answer most closely reflects your use of the following Lean practices?
  Wide Use Some Use No but Plan to Use No and no Plan to use Don't Know
Reduction of waste (muda)          
Reduction of variation          
Workplace Organization – 5S          
Standardized Work, methods sheets          
Error Proofing (Poka-Yoke)          
Quick Set-up/Change over – (SMED)          
Level Production (Heijunka scheduling, load leveling)          
Small Lot (1 piece flow, lot size 1)          
In-plant Pull Systems (Kanban)          
Value Stream Mapping          
Cellular manufacturing/line design          
JIT (Just in Time) production          
Other widely used                  
8. Which of the following metrics do you use for your Lean initiative and for those you use, how effective are they?
  Very effective Somewhat effective Not very effective Not used
Scrap        
Rework        
1st pass yield        
Defects        
Changeover time        
Schedule attainment        
Cycle time variation        
Inventory turns or total inventory levels        
% value added time        
Planned vs. unplanned maintenance        
% of material delivered JIT to line        
On-time delivery to customer requested date        
On-time delivery to commited/promise date        
Other effective metrics              
9. Are all plants using the same Lean and Metrics methods & techniques?
  Yes all Most, not all A few No Don’t know
         
10. For key Lean metrics in use today, to what degree are they standard? (check the first one that applies - Note: cannot deselect)
 
Industry standard calculation & definition  
Industry standard definition  
Company standard  
Division standard  
Not standard (per plant or facility)  
11. Please determine which role performs the described actions at your company or location:
  Executive team One executive Project or team leader Cont. Improvement, Ops Excellence or Similar Plant/facility manager Supervisors Everyone in the process Everyone in the facility
Who defines and sets calculations for metrics?                
Who reviews the metrics for alignment to initiative intent?                
Who conducts analysis and tracks performance to the metrics?                
Who is held accountable to improve against the metrics?                
Who designs and tracks business process response to metrics?                
12. Are you pursuing Real-time Enterprise ”near real time mfg information flow”? If yes, proceed to next question; if no please skip to question 20.
  Yes Net yet; Plan to No
     
13. Which answer most closely reflects your use of the following Real-time Enterprise practices?
  Wide Use Some Use No but Plan to Use No and no Plan to use Don't Know
Automated business processes          
Integrated systems allow collaborative decisions          
Identify aligned KPIs with real time data collections          
Map stakeholders’s accountabilities          
Automated business activity monitoring/alerts/alarms          
Portals or other web applications          
Non-fragile integration/Message-oriented middleware/SOA          
Searchable Knowledge management          
Real-time plant-to-enterprise connections          
Business continuity infrastructure          
Security infrastructure          
Wireless devices that connect to manufacturing systems          
Visibility/alerts/alarms          
Ad hoc applications: Web services/SOA/Composite apps./Mash-ups          
14. Which of the following metrics do you use for your Real-time Enterprise initiative and for those you use, how effective are they?
  Very effective Somewhat effective Not very effective Not used
Schedule compliance        
Workforce performance        
Order to delivery cycle time        
OEE (overall equipment effectiveness)        
Overall time-to-market        
Overall order-to-delivery        
Improved perfect order percentage        
Plant/factory inventory        
Supply chain inventory        
Inventory turns        
Customer satisfaction        
Profitability        
Speed to respond to events/alarms        
Data quality        
Data security        
Systems uptime        
Other effective metrics              
15. Are all facilities using the same Real-time Enterprise and Metrics methods & techniques?
  Yes all Most, not all A few No Don’t know
         
16. For key Real-time Enterprise metrics in use today, to what degree are they standard? (check the first that applies - Note: cannot deselect)
 
Industry standard calculation & definition  
Industry standard definition  
Company standard  
Division standard  
Not standard (per plant or facility)  
17. What role is responsible for the following action?
  Executive team One executive Project or team leader IT Plant/facility manager Supervisors Everyone in the process Everyone in the facility
Who is defines and sets calculations for these metrics?                
Who reviews the metrics for alignment to initiative intent?                
Who conducts analysis and tracks performance to the metrics?                
Who is held accountable to improve against the metrics?                
Who designs and tracks business process response to the metrics?                
18. Which of the following solutions and technologies does your company use to support real-time enterprise initiatives?
  Use widely Some use Not now but planning to buy No and no plans Don't know
ERP - Enterprise Resources Planning          
PLM - Product Lifecycle Management          
SCM - supply chain mgmt. incl. planning, scheduling, execution          
CRM - Customer relationship management          
MES - Manufacturing Execution System or plant floor functions          
Plant dashboards/mfg. intelligence/operations performance mgmt.          
Data historian          
SCADA - supervisory control & data acquisition          
Control system software          
Quality Management          
LIMS - laboratory information management          
Integration Middleware          
Homegrown Access/Excel databases          
BPM - Business process management or workflow          
BAM - Business Activity Monitoring/ alerts/alarms          
BI - business intelligence, data warehouses, data marts          
Portal          
Other collaboration software          
SOA - Service Oriented Architecture          
19. What is your approach for unifying plant level systems across multiple manufacturing sites? (select all that apply)
 
Centralized database  
Standard codes and common terminologies  
Standardized reporting across plants  
Standardized KPIs across plants  
Standardized technology architecture  
Guidelines for systems selection  
Corporate governance structure for manufacturing  
Executive level manufacturing leader  
20. Are you pursuing Total Quality (total quality as quality measured not simply by end-of-line defects but during the process and/or as process capability)? If yes, proceed to next question; if no, please proceed to question 26.
  Yes Net yet; Plan to No
     
21. Which answer most closely reflects your use of the following Quality practices?
  Wide use Some use No, but plan to use No, and no plan to use Don't Know
Customer-defined quality & value (DOE, FMEA)          
SPC/SQC Statistical Process or Quality Control          
CAPA Corrective and Preventative Actions          
Continuous improvement (Kaizen)          
Improvement teams or Quality circles          
Six Sigma training & methodologies          
Fishbone diagramming for root cause          
Empowered employees          
Daily shift meetings focused on quality          
Quantified goals          
Benchmarking          
Process capability measurement (CpK)          
Cross-functional process0 mgmtt or Quality Execution across every step          
Supplier partnership          
Other                  
22. Which of the following metrics do you use for your Quality initiative and for those you use, how effective are they?
  Very effective Somewhat effective Not very effective Not used
Market share        
Defects        
First-pass Yield        
Total throughput Rolled Yield        
Process Capability per line (CpK)        
Scrap/rework as % of sales        
Return rate and/or Warranty costs        
Customer reject rate (PPM)        
Time to close CAPAs        
Repeat of closed CAPAs        
Employee improvement suggestions/year        
Employee cross-training        
Supplier quality        
Other effective metrics              
23. Are all facilities using the same Quality metrics, methods & techniques?
  Yes, all Most, not all A few No
       
24. For key Quality metrics in use today, to what degree are they standard? (check the first that applies - Note: cannot deselect)
 
Industry standard calculation & definition  
Industry standard definition  
Company standard  
Division standard  
Not standard (per plant or facility)  
25. Who is responsible for these Quality metrics?
  Executive team One executive Quality Department Continuous Improvement, Six Sigma, Ops Excellence Plant/facility manager Supervisors Everyone in the process Everyone in the facility
Who is responsible for these Total Quality metrics?                
Who reviews the metrics for alignment to initiative intent?                
Who conducts analysis and tracks performance to the metrics?                
Who is held accountable to improve against the metrics?                
Who designs and tracks business process response to metrics?                
26. What makes these KPIs for any of your initiatives listed above effective for your company or division? (check all that apply)
  Yes No
High level of detail or granularity    
Standard calculation    
Explicit correlation (aggregates multiple pieces of data for larger vi    
Alignment with key business needs    
Used in diagnostic business processes    
Standardized across our company    
Standardized across our industry    
Executive compensation rests on it    
Manager compensation rests on it    
Everyone’s compensation rests on it    
27. Are all plants sharing KPIs and performance data for major initiatives such as Lean, Real-time Enterprise, and Total Quality?
  Yes, complete Yes, some Very little No Don’t know
         
28. From what sources do you collect the data for your Lean, Real-time Enterprise and/or Total Quality initiatives?
  Yes very common Yes Sometimes No Don't Know
Equipment/sensors automatically        
Control system automatically        
Data historian automatically        
SCADA/HMI (Supervisory control)        
Data collection/bar code/RFID        
MES (Manufacturing Execution System)        
WMS (Warehouse Mgmt. System)        
ERP / PLM / SCM / CRM - Enterprise system        
PLM (Product Lifecycle Mgmt.)        
SCM (Supply Chain Mgmt.)        
CRM (Customer Relationship Mgmt.)        
BAM/Alerts/Alarms/Workflow        
Other IT Infrastructure        
29. Frequency at which various metrics processes typically occur
  Annually Quarterly Monthly Weekly Daily Every shift Hourly On-demand or near real-time
How frequently do you collect the data?                
How frequently do you display or view the metrics?                
How frequently do you expect to view the metrics in 12 months?                
What is the ideal frequency for viewing these metrics?                
How quickly can people react to a KPI that is out of line?                
30. Which of the following is the major issue causing discrepancy between current and ideal frequency for metrics?
  IT challenges Business process constraints Lack of will to change Lack of vision or understanding Lack of budget Don't know
Data collection            
Display of results            
Use of the metrics Information            
31. How frequently does your organization re-evaluate how effective all of these types of metrics are in driving performance?
  Monthly Quarterly Annually Rarely Event-driven
How frequently do you re-evaluate metrics effectivity or alignment?          
How frequently do you re-evaluate the use of metrics in processes?          
Evaluate the process to gather, process & disseminate metrics?          
32. Please indicate your company's most common use of and experience with operations or performance dashboards or manufacturing intelligence systems.
  Wide use Actionable Wide use Not Actionable Some use Actionable Some use Not Actionable Not used but in Plans Not used and No Plans
           
33. Select which description is most typical of your level of drill-down capability for aggregate metrics (example: scrap is 2% - can drill down to machine/part/process/operator)
  No drill down - must research Some drill-down Good drill down Complete drill-down Don't know
         
34. Is drill down typically in fixed or ad hoc selections?
  All fixed Mostly fixed, some ad hoc Mostly ad hoc, some fixed All ad hoc N/A or Don't know
         
35. Why are you collecting performance metrics or KPI data on lean, real-time enterprise and quality? (choose the most important driver)
  For an initiative For a customer Regulatory or industry compliance Management requested it For core improvement needs
         
36. Generally speaking, what percent of your operation’s metrics are in conflict with other metrics in your company?
  >10% 10-30% 30-50% 50-75% >75%
         
37. Where do the conflicts most commonly occur? (select the one most frequent)
 
Between levels (viz. aggregated supply chain and line-level metrics)  
Between departments (viz. distribution vs. production)  
Within a department (viz. throughput vs. profitable mix in the plant)  
Between our company and trading partners (customers or suppliers)  
Between various customers or various suppliers  
38. Annual revenue of Company/division/location to which answers pertain
  Under $500 million $500 million to $2 billion Over $2 billion
     

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