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What Should Be Measured
Few of the measures used by World Class
Manufacturers are new. What is new is the separating of the
traditional financial reporting system, still used for external
reporting purposes, from the information system used by managers
for decision making and to run the business. In addition, the
methods used to convey information are much more varied, using
charts, graphs, pictures and signals in addition to the
traditional numerical report formats.
In his excellent book, Performance
Measurement for World Class Manufacturing, Brian Maskell
indicates the following as some categories considered important by
World Class companies. Both quantitative and qualitative measures
must be considered, along with trends and velocity of improvement:
• Delivery Performance: Timeliness and
accuracy of vendor order placement and delivery; accuracy of
shop floor schedule in accordance with customer requirements;
ability to meet, but not exceed, production schedule; correct
quality and quantity delivery to customer on time per customer
requirements; analysis of lost sales due to delivery
deficiencies.
• Process Time: Manufacturing cycle
times; Ratio of promised customer delivery lead time to
cumulative production lead time; Setup times, average and
variability; Material and tooling availability; Material
movement distances; Unscheduled machine down time; Order
entry, purchase order processing, customer inquiry response
and other administrative process times.
• Production Flexibility: Number of
parts and levels in bills of material; Percentage of standard
parts; Number of production processes and processes used on more
than one part; Number of new product launches; New product
launch cycle time; Degree of cross training of production
personnel.
• Quality: Vendor and production
quality measures; Data accuracy of inventory, bills of
materials, routings and forecast; Design process quality and
number of engineering changes; Number of warranty claims,
customer complaints and recalls; Cost of poor quality;
• Financial: Scrap, rework, excess
queuing, excess movement, amount of non value added activity and
other waste measurement; Inventory turns by class (raw
material, WIP, finished goods) and product; Activity based
costing product cost valuation; Total value of usable finished
product produced per period per employee; Total cost and output
value ratios; Time based overhead usage.
The final category of measures for World Class
Companies is, in many ways, the most important, but is also the
most difficult to quantify. Measuring the effectiveness of the
social organization is critical to success at the World Class
level.
There are some factors, such as safety and
environment that lend themselves to quantification, and others,
such as education and
training levels and team participation that can
be measured in quantity if not in quality, but many cannot yet be
successfully quantified.
To be sure there are questionnaires, survey
instruments and performance evaluation formats that claim to
measure things like work force morale, teamwork, involvement and
leadership ability. However, although these may be valuable
indicators, they are no substitute for constant contact,
communication and participation by managers, both within and
between departments. With all the systems of controls at the
disposal of the present day organization, it is still up to
managers to ensure that the activities being performed are moving
the organization in the direction of its goals, objectives and
vision.
Evaluation of a Control System
Evaluation of a control system is a two stage
process. The first step is to list the controls used to measure
the organization down the left side of a matrix and list the
characteristics (economy, meaningfulness, etc.) across the top.
Evaluate which controls do not fulfill the control
characteristics. This will give you an indication of how well your
control system fulfills its purpose.
The second step to determine the information
required to evaluate the efficiency and effectiveness of the
organization in meeting its goals and objectives. This is not an
easy task and requires more of what Peter Senge in The Fifth
Discipline calls skills of inquiry rather than skills of
advocacy. This means that this is not an exercise of one
department defending their position against another. Rather it is
an inquiry into what it actually takes to fulfill organizational
goals and how best to measure each department's contribution to
that effort. An interesting approach to this problem is suggested
by Tichy in Control Your Destiny or Someone Else Will.
By comparing existing control systems with a
goal oriented control system, the typical organization finds that
it wastes a great deal of time, energy and money on controls that
are meaningless at best and counterproductive at worst. A major
reevaluation of the system of controls is often called for since
the organization has probably changed in response to global market
conditions much more rapidly than the measures used to manage it.
In summary, systems of controls are necessary to measure
performance in an organization. However, if this system of
controls is not constantly evaluated and modified to reflect the
changing conditions in which the organization finds itself and the
changing information technologies available to it, the
organization will find itself falling behind in the World Class
race, sabotaged by its lack of understanding of its own purpose.
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