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Performance Measurements

 

PART III. 

 

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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