By John Brandt
Manufacturing excellence doesn’t just happen. Plants near or at world-class status are far more likely to pursue improvement methodologies and best practices.
Executives at most plants understand that process improvement is important or highly important to their success (84%). But there’s an enormous gap between plants near or at world-class status and those furthest from world-class status when it comes to executing process improvements. For example, 93% of plants near or at world-class status follow an improvement methodology vs. just 80% of plants furthest from world-class. At the same time, plants near or at world-class status have 75% of their workforce (median) engaged in the improvement methodology vs. just 25% of plants furthest from world-class.
MPI also asked manufacturers to report on use of various operational best practices. For example, 50% of plants near or at world-class status use benchmarking vs. just 36% of plants furthest from world-class status. And a majority of plants near or at world-class status (52%) have five or more best practices/programs in place, vs. just 35% of plants furthest from world-class status.
Operations Execution (% of plants)
Furthest from world-class
Near or at
|Process improvement highly important or important (% of plants)|
|Use of lean manufacturing (% of plants)|
|Use of any improvement methodology (% of plants)|
|Use five or more operations practices/programs (% of plants)|
|% of workforce fully engaged in improvement methodology(ies) (medians)|
|% of processes addressed with improvement methodology(ies) (medians)|
How well does your plant execute on process improvement?
Contact The MPI Group to learn more about the 2011 MPI Manufacturing Study findings and the 2011 Next Generation Manufacturing Study findings.