DEM-01 |
Demand forecast model |
Score 1 - Company does not have a formal model to forecast demand and uses only the experience of the sales staff to forecast main items. |
Score 3 - Company has a formal model to forecast demand, with software, but only makes the forecast for main items. |
Score 5 - Company has a formal model to forecast demand, with software, and makes the forecast for all items. |
DEM-02 |
ABC management of demand |
Score 1 - Company does not have a formal model for ABC management of demand. |
Score 3 - Company has, and eventually uses, a formal model for ABC management of demand, with software. |
Score 5 - Company has, and always uses, a formal model for ABC managgement of demand, with software. |
DEM-03 |
Market analysis |
Score 1 - Company does not have a formal model for communication channel with the main customers. |
Score 3 - Company has, and eventually uses, a formal model for communication channel, with software and other techniques, for the main customers. |
Score 5 - Company has, and always uses, a formal model for communication channel, with software and other techniques, for the main customer. |
DEM-04 |
Forecast reliability |
Score 1 - Company misses more than 40% of demand forecast. |
Score 3 - Company misses between 20% and 30% of demand forecast. |
Score 5 - Company misses less than 10% of demand forecast. |
DEM-05 |
Concentration degree |
Score 1 - Company does not have demand concentration. |
Score 3 - Company has more than 50% of the demand at less than 30% of items. |
Score 5 - Company has more than 50% of the demand at less than 10% of items. |
DEM-06 |
Frequency degree |
Score 1 - Company has less than 20% of items with monthly sales frequency. |
Score 3 - Company has between 30% and 40% of items with monthly sales frequency. |
Score 5 - Company has more than 50% of items with monthly sales frequency. |
DEM-07 |
Confirmed demand degree |
Score 1 - Company has less than 20% of confirmed demand before beginning production. |
Score 3 - Company has between 40% and 30% of confirmed demand before beginning production. |
Score 5 - Company has more than 50% of confirmed demand before beginning production. |
DEM-08 |
Demand response |
Score 1 - PPC of company accesses the information of demand forecast, or confirmed orders in advance of the promised delivery date. |
Score 3 - PPC of company accesses the information of demand forecast, or confirmed orders, in advance of, or equal to, the promised delivery date. |
Score 5 - PPC of company accesses the information of demand forecast, or confirmed orders, after the promised delivery date. |
Product indicators
|
Description of the scores
|
PRO-01 |
Concurrent Engineering |
Score 1 - Company does not have a formal multifunctional model to design new products. |
Score3 - Company has a formal multifunctional model to design new products, supported by an efficient communication channel. |
Score 5 - Company has a formal multifunctional model to design new products, supported by an efficient communication channel, which involves suppliers and final consumers. |
PRO-02 |
Parameter setting of design |
Score 1 - Company does not use parameter setting of design |
Score 3 - Company uses parameter setting of design for a few product families. |
Score 5 - Company systematically uses parameter setting of design for all product families. |
PRO-03 |
Calendar of product development |
Score 1 - Company does not have a calendar of product development. |
Score 3 - Company has a calendar of product development for a few items. |
Score 3 - Company has a calendar of product development for all items. |
PRO-04 |
Special order negotiation |
Score 1 - Company accepts special orders, despite parameter setting of design. |
Score 3 - Company accepts special orders, if they partially adhere to the parameter setting of design. |
Score 5 - Company accepts special orders, if they totally adhere to the parameter setting of design. |
PRO-05 |
Internal defects percentage |
Score 1 - Company has, on average, more than 0.1% defects, which means more than 10,000 parts per million. |
Score 3 - Company has, on average, less than 0.1% defects, which means less than 1,000 parts per million. |
Score 5 - Company has, on average, less than 0.1% defects, which means less than 1,000 parts per million. |
PRO-06 |
Variety degree |
Score 1 - In the portfolio of the company, the average ratio between the number of families and the number of items within these families is greater than 100. |
Score 3 - In the portfolio of the company, the average ratio between the number of families and the number of items within these families is between 50 and 100. |
Score 5 - In the portfolio of the company, the average ratio between the number of families and the number of items within these families is lower than 100. |
PRO-07 |
Life cycle |
Score 1 - If the rate between the portfolio lifetime and its programming cycle is lower than 4. |
Score 3 - If the rate between the portfolio lifetime and its programming cycle is between 6 and 10. |
Score 5 - If the rate between the portfolio lifetime and its programming cycle is greater than 10. |
PRO-08 |
Leftover percentage |
Score 1 - If the leftover percentage of the portfolio items is greater than 20%. |
Score 3 - If the leftover percentage of the portfolio items is between 5% and 10%. |
Score 5 - If the leftover percentage of the portfolio items is lower than 1%. |
PPC indicators
|
Description of the scores
|
PPC-01 |
Master Production Planning (MPP) |
Score 1 - Company does not have a formal Master Production Planning (MPP) model. |
Score 3 - Company has, and uses monthly, a formal Master Production Planning (MPP) model with software. |
Score 5 - Company has, and uses weekly, a formal Master Production Planning (MPP) model integrated to the Enterprise Resource Planning (ERP). |
PPC-02 |
Material Requirement Planning (MRP) |
Score 1 - Company does not have an MRP integrated system, but works with spreadsheets or isolated systems. |
Score 3 - Company has, and uses monthly, an MRP integrated system, with software. |
Score 5 - Company has, and uses weekly, a formal MRP system integrated to the Enterprise Resource Planning (ERP). |
PPC-03 |
Production capacity analysis |
Score 1 - Company does not have a capacity planning system. |
Score 3 - Company has a capacity planning system with no MPP integration. |
Score 5 - Company has a capacity planning system with MPP integration, and cycle time, production rate and stock level calculation. |
PPC-04 |
Departmental PPC |
Score 1 - Company does not have PPC for departments. |
Score 3 - Company has central PPC bases for the departments with periodic communication. |
Score 5 - Company has PPC bases for the departments linked by a communication channel, within which flows all the necessary information |
PPC-05 |
Integrated schedule system |
Score 1 - Company does not have a PPC system to manage pulled flows. |
Score 3 - Company has two distinct PPC systems to manage pulled and pushed flows. |
Score 5 - Company has two integrated PPC systems to manage pulled and pushed flows. |
PPC-06 |
Plan and Schedule cycle |
Score 1 - Company has a plan and schedule cycle with monthly, or greater, frequency. |
Score 3 - Company has a plan and schedule cycle with half a month frequency. |
Score 5 - Company has a plan and schedule cycle with weekly, or lower, frequency. |
PPC-07 |
On time delivery percentage |
Score 1 - Company has on-time delivery at lower than 40% of the orders. |
Score 3 - Company has on-time delivery at between 60% and 80% of the orders. |
Score 5 - Company has on-time delivery at greater than 90% of the orders. |
PPC-08 |
Value aggregation percentage |
Score 1 - Company has production lead time 30 times greater than standard lead time from engineering. |
Score 3 - Company has production lead time between 10 and 20 times the standard lead time from engineering. |
Score 5 - Company has production lead time lower than 5 times the standard lead time from engineering. |
PPC-09 |
Inventory turnover |
Score 1 - Company has three months, or greater, inventory turnover. |
Score 3 - Company has a month’s inventory turnover. |
Score 5 - Company has a week’s turnover, or lower. |
PPC-10 |
Extra time percentage |
Score 1 - Company uses 20%, or greater, of unplanned extra time to meet the delivery dates. |
Score 3 - Company uses between 10% and 20% of unplanned extra time to meet the delivery dates. |
Score 5 - Company uses 5%, or lower, of unplanned extra time to meet the delivery dates. |
Shop floor indicators
|
Description of the scores
|
SHF-01 |
Volume flexibility |
Score 1 - Company does not have varied sizes of equipment and must use larger equipment to produce more than the customer needs. |
Score 3 - Company has small, medium, and large sizes of equipment, but must use bigger equipment to produce more than the customer needs. |
Score 5 - Company has small, medium, and large sizes of equipment and use equipment in proportion to customer needs. |
SHF-02 |
Single Minute Exchange of Dies (SMED) |
Score 1 - Company does not have a formal process of critical analysis for machine setup. |
Score 3 - Company has a formal group that eventually makes the critical analysis of the machine setup. |
Score 5 - Company has a formal group guided by goals of continuous reduction of machine setup times, which results in a critical analysis of setup times. |
SHF-03 |
Focused production |
Score 1 - Company has less than 10% of capacity focused on specific family items. |
Score 3 - Company has between 20% and 30% of capacity focused on specific family items. |
Score 5 - Company has more than 50% of capacity focused on specific family items. |
SHF-04 |
Total Productive Maintenance |
Score 1 - Company only makes corrective maintenance. |
Score 3 - Company makes preventive maintenance, but lacks a broader maintenance program. |
Score 5 - Company has a Total Productive Maintenance program and continually trains technicians. |
SHF-05 |
Polyvalence program |
Score 1 - Company does not have a formal polyvalence program for technical training of employees. |
Score 3 - Company has a partial polyvalence program for technical training of employees. |
Score 5 - Company has a polyvalence program for technical training of all employees. |
SHF-06 |
Standard routine |
Score 1 - Company does not use standard routine. |
Score 3 - Company uses standard routine, balanced with the cycle time, only for the assembly line. |
Score 5 - Company uses standard routine, with polyvalent employees, balanced with the cycle time for the assembly line and manufacturing cells and keeps standard routine sheets available at the shop floor. |
SHF-07 |
Leveling degree |
Score 1 - Company has the leveling factor (average production lot size / average order size) > 2. |
Score 3 - Company has the leveling factor 1.3 < (average production lot size / average order size) > 1.5. |
Score 5 - Company has the leveling factor (average production lot size / average order size) < 1.1. |
SHF-08 |
Setup percentage |
Score 1 - Company has setup time 30% greater than production time. |
Score 3 - Company has setup time between 10% and 20% of production time. |
Score 5 - Company has setup time lower than 5% of production time. |
SHF-09 |
Productive indices |
Score 1 - Company has a real productivity lower than planned productivity. |
Score 3 - Company has a real productivity equal to planned productivity. |
Score 5 - Company has a real productivity greater than planned productivity. |
SHF-10 |
Non-planned breakdown indices |
Score 1 - Company eventually has production downtime because of equipment breakdown. |
Score 3 - Company rarely has production downtime because of equipment breakdown, but still has emergency maintenance before imminent breakdowns. |
Score 5 - Company never has production downtime because of equipment breakdown. |
SHF-11 |
Polyvalence indices |
Score 1 - Company has less than 20% of polyvalent employees. |
Score 3 - Company has between 40% and 60% of polyvalent employees. |
Score 5 - Company has more than 80% of polyvalent employees. |