ASR Survey Results September 2008

ASR Survey Results September 2008
What is your company’s dominant manufacturing technology?
ERP/MRP
   
66.10%
Lean
   
35.59%
TOC
   
10.17%
Other
   
8.47%
No Answer
   
1.69%
 
Which of the following are sources of variability and volatility in your environment?
Inaccurate forecasts
   
62.71%
Demands for leaner inventories
   
61.02%
Material shortages
   
59.32%
Long lead time parts/components
   
59.32%
More product complexity and/or customization
   
49.15%
Global sourcing and demand
   
45.76%
More product variety
   
38.98%
New materials
   
30.51%
Complex synchronization issues
   
30.51%
More offshore suppliers
   
30.51%
Shortened product life cycles
   
25.42%
No Answer
   
8.47%
 
Could you tell us briefly why ASR interests you?
View the text responses
 
Do material shortages ever interfere with meeting your schedules?
Sometimes
   
49.15%
Often
   
42.37%
Rarely
   
10.17%
Never
   
1.69%
No Answer
   
1.69%
 
Do purchased parts shortages ever interfere with meeting your schedules?
Sometimes
   
49.15%
Often
   
35.59%
Rarely
   
11.86%
No Answer
   
3.39%
Never
   
1.69%
 
Do manufactured or assembled component shortages ever interfere with production schedules?
Sometimes
   
38.98%
Often
   
27.12%
Rarely
   
23.73%
Never
   
5.08%
No Answer
   
5.08%
 
If “too much of the wrong inventory, too little of the right” applies to your operations, how long has this been going on?
Years
   
62.71%
Doesn’t apply to us
   
15.25%
Months
   
13.56%
Only recently
   
5.08%
No Answer
   
3.39%
 
If your service levels, or fill rates, or on-time deliveries aren’t where they should be … how long has this been going on?
Years
   
49.15%
Doesn’t apply to us
   
22.03%
Months
   
13.56%
Only recently
   
10.17%
No Answer
   
5.08%
 
If there’s too much expediting, premium freight and overtime involved in your operation, how long has this been going on?
Years
   
57.63%
Months
   
16.95%
Only recently
   
13.56%
Doesn’t apply to us
   
8.47%
No Answer
   
5.08%
 
Have any of these headaches continued at a significant level through more than one manufacturing system implementation?
Yes
   
55.93%
No
   
28.81%
No Answer
   
15.25%
 
Do employees develop “workarounds” using spreadsheets and Access databases (for example) because they feel they can’t work effectively within the formal planning system?
Too many
   
59.32%
Just a few
   
33.90%
No Answer
   
5.08%
Never
   
3.39%
 
Approximately how many levels are there in your Bill of materials?
5 – 7
   
38.98%
2 – 4
   
33.90%
8 or more
   
22.03%
No Answer
   
6.78%
 
Approximately how many employees are there in your plant? (All departments).
500+
   
44.07%
101 – 500
   
27.12%
51 – 100
   
15.25%
Fewer than 50
   
6.78%
No Answer
   
6.78%
 
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