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Thank you for participating in the Products Finishing Top Shops benchmarking survey for liquidsand powder coating, which highlights the attributes shared by leading U.S. and North Americanfinishing businesses. In return for completing the survey, a report of findings will be provided so you may benchmarkyour shop's performance with other shops in the finishing industry. This is a great tool for shopswho want to improve efficiencies and increase productivity. We are also happy to recognize in Products Finishing those shops designated as Top Shops. Wewill supply artwork and promotional material to let your customers, employees and industry peersknow your finishing shop operation is one of the premier facilities in North America. Several shopswill also be profiled in an upcoming issue of Products Finishing. The survey covers four areas of shop operations:
Finishing TechnologyFinishing Practices and PerformancesBusiness Strategies and PerformancesTraining and Human Resources
Our survey and analysis experts have ensured that the scoring matrix used to identify top shopsenable any shop, regardless of size, location, diversification, etc. to qualify as a Top Shop.
All you need to do is complete the survey. Remember to answer each question as only consistentresponders will receive the report. All responses are confidential to the staff of Products Finishingand will not be shared by any outside agency or organization.
This survey must be completed by by June 1, 2017. If you have any questions, please contact TimPennington, Editor, Products Finishing, at [email protected]. If you want to keep arecord of your responses, we suggest you print a copy of each page with your responses beforeselecting 'next' to advance to the next page/question.
Liquid and Powder Coatings, Electrocoat
2017 Products Finishing Top Shops Benchmarking Survey
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Click here if you'd like to download a pdf of the survey to review. You can revisit this site to enteryour answers or return a completed survey pdf print out to us via mail or fax (instructions on howto do so are found at the end of the survey.)
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Company Information
2017 Products Finishing Top Shops Benchmarking Survey
1. To receive benchmarking reports of survey findings, provide your email address
Your Name:
Title:
Company Name:
Address:
City:
State: -- select state --
Zip:
Country:
Website:
Company phonenumber:
2. To be recognized as a 2016 Top Shop finishing operation provide the following information:
All responses will remain confidential to Products Finishing and will not be shared by any outside organization.
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Finishing Practices and Performances
2017 Products Finishing Top Shops Benchmarking Survey
3. Which of the following practices and improvement methodologies does your business use? (Select ALLthat apply)
5S workplace organization
Benchmarking
Continuous improvement program
Customer Surveys
Just-in-Time movement of materials
Kaizen events/blitzes
Kanban and pull systems
Overall Equipment Effectiveness (OEE)
PCI Certification
Quality certs (i.e. ISO, NADCAP, etc.)
Six Sigma
Total quality management
Value-stream mapping
None of the above
Please provide the following measures for your business in 2016 (Please enter numbers only as decimals,symbols and words are not accepted.)
4. Order lead time in 2016 (average days from receipt of order to delivery to customer)
5. On-time delivery rate in 2016 (percentage of goods delivered on time)
6. Finished product first-pass quality yield in 2016 (percentage of product that passed final inspection onfirst attempt; no re-work required)
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7. Finishing usage in 2016 (average hours finishing equipment is in production per 24-hour day)
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Finishing Practices and Performance
2017 Products Finishing Top Shops Benchmarking Survey
Environmental management
Parts inspection
Analytical testing
Hazardous waste management
Training
8. Please estimate the number of labor-hours your shop spends each week on each of the following tasks. (please enter numbers only; decimals, symbols, and words are not accepted):
Please rate each item in the question that follows in the interest of data quality and to receive the report.
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Do not have written
proceduresHave written procedures,
but need updatingHave written procedures
and they are current
Application Procedures(Liquid and/or PowderCoating)
WasherQuality/Performance
Testing Procedures
9. Please select the rating that best describes your business practice in each of the areas listed below. (Select ONE rating per row)
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
Please provide the following financial measures for your business in 2016. Note these measures usesimple formulas to allow important comparisons across shops yet protect you from having to disclosespecific financials. This information will be kept strictly confidential. (Please enter numbers only; decimals,symbols and words are not accepted EXCEPT at Q13 where a minus sign can be added if the number isnegative.)
10. Gross sales/number of finishing lines in 2016 (in dollars)
11. Gross sales/number of employees in 2016 (in dollars)
12. Net income/gross sales in 2016 (as a percentage)
13. Annual sales growth rate in 2016 (as a percentage; add a minus sign if the number is negative): [(gross sales 2016 - gross sales 2015)/gross sales 2015]
14. Capital equipment expenditure/gross sales in 2016 (as a percentage)
15. Capacity utilization in 2016 (as a percentage)
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
Less than 20%between 20 -
39%between 40 -
59%between 60 -
79% 80% or more Don't know
2016
2015
2014
16. About what percentage of your business' profit objective was met in each of the past 3 years? (SelectONE per row)
17. What are your expectations as far as order volume for your business in 2017? (Select ONE response)
Above target
At target
Below target
Not sure
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
Please rate each item in the question that follows in the interest of data quality and to receive the report.
No records
are keptRecords are kept,but not analyzed
Records are keptand analyzed
Booth maintenance
Gun maintenance
Pump maintenance
Oven maintenance
Coating material lot nos.
Preventativemaintenance logs
Customer returns
Electricity use
Nozzle pressure
Waste treatmentchemical reagent use
Water use
Rinse water quality
18. Please select the rating that best describes your business practice in each of the areas listedbelow. (Select ONE rating per row)
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
19. Which of the following supply chain practices does your business use? (Select ALL that apply)
Certification of major suppliers
Collaborative design with customers
Collaborative design with suppliers
Customer satisfaction surveys
Just-in-time deliveries from suppliers
Just-in-time deliveries to customers
Utilizing customer forecasts
Vendor-managed or -owned inventories
Vendor-managed or -owned inventories for customers
None of the above
20. Which of the following sales/marketing tools are effective for your business? (Select ALL that apply)
Blogs
Brochure/catalogs
Customer tours of shop
Email promotions
Online - advertising
Online - company website
Print advertising (i.e. magazines)
Sales personnel
Social media (Facebook, Twitter, LinkedIn)
Trade shows/events
Trade associations
YouTube
None of the above
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
You may need to refer to company data to answer the following questions. Please take the time to do so in the interest of data qualityand to receive the report.
21. For independent shops, how many active customers (i.e. customers paying for work) did your businesshave in 2016? (Please enter a number; decimals, symbols, and words are not accepted.)
22. For independent shops, thinking of your customers in order from largest to smallest, what percentage ofyour shop's total 2016 sales came from the top 20% of your customers? As an example, if you had 10total customers, you would divide the 2016 sales of your top 2 customers into your shop's total 2016 sales.(Please enter a number; decimals, symbols, and words are not accepted.)
23. For independent shops , what was the customer retention rate for 2016? (% of customers retained fromthe previous year. Please enter a number; decimals, symbols, and words are not accepted.)
24. What percentage of business quoted was actually booked? (business booked as a % of businessquoted. Please enter a number; decimals, symbols and words are not accepted.)
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Business Strategy and Performance
2017 Products Finishing Top Shops Benchmarking Survey
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Liquid Application Equipment
Powder Application Equipment
Racking Equipment
Testing Equipment
Spray Booths (liquid/powder)
Washers
Full Turnkey Systems
Chemicals
Coating Materials
Ovens
Other
25. How much do you estimate your shop will spend on purchasing these categories for direct involvementin finishing in 2017? (Enter '0' if you expect to make no investment in a category in 2017. Please enter anumber; decimals, symbols and words are not accepted.)
26. What coatings or services would you like to add to your shop?
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Monitoring Practices
2017 Products Finishing Top Shops Benchmarking Survey
What equipment and/or operations does your shop monitor? (Select ALL that apply in each category. Select 'None in this category' if no equipment and/or operations are monitored in a given category.) POWDER COATING
27. Cleaning Baths
Pressure/Agitation
Temperature
Time
Chemical Concentration
Impurity Content
Dump Schedule
None in this category
28. Rinse Baths
Pressure/Agitation
Temperature
Time
Impurity Concentration
Overflow Rate
Dump Schedule
None in this category
29. Abrasive Blast Process
Incoming part assessment
Abrasive media flow
Nozzle air pressure
Dwell time
Dust collector efficiency/air flow
Working mix
Surface cleanliness
None in this category
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30. Powder Booth and Equipment
Temperature of parts entering booth
Proper line speed
Ground checked
Air dryer and filter
Booth temperature and humidity
Air balance
Rotary seive clean and operational
Powder flow
Vent assist air pressure
Vent on feed hooper
Reclaim seive
Powder guns
Virgin/reclaim ratio
None in this category
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Monitoring Practices
2017 Products Finishing Top Shops Benchmarking Survey
What equipment and/or operations does your shop monitor? (Select ALL that apply in each category.Select 'None in this category' if no equipment and/or operations are monitored in a given category )
LIQUID COATING
31. Part Appearance
Inspection criteria posted
Adequate lighting
Paint racks maintained
None in this category
32. Paint Mixing
Paint mixing rooms controlled
FIFO system utilized
Paint agitation/time and reduction
Viscosity and temperature
Proper filter size
Pump pressures
Circulation flow meter, pressure gage
Bag filter pressures
None in this category
33. Primer
Incoming parts inspected
Booth balance
Booth temperature and humidity
Film thickness
Atomizer parameters set
None in this category
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34. Basecoat
Incoming parts inspected
Flashtimes set
Booth temperature and humidity
Atomizer parameters set
Film builds
None in this category
35. Clearcoat
Incoming parts inspected
Flashtimes set
Booth temperature and humidity
Atomizer parameters set
Cure
None in this category
36. Final Part Inspection
Inspection criteria posted
Adequate lighting
Defects tracked
FTT monitored
Scrap and repaints tracked
None in this category
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Profile Questions
2017 Products Finishing Top Shops Benchmarking Survey
37. Which category best describes your business’ relation to its customer base? (Select ONE response)
Captive shop (component of a larger company)
Contract shop (independent shop with 50% or more contract work)
Job shop (independent shop with less than 50% contract work)
You may need to refer to company data to answer the following questions. Please take the time to do so in the interest of data qualityand to receive the report.
38. As of the end of 2016, how many years has your company been in business? (Enter a number)
39. How many finishing lines did your shop have in production in 2016? (Enter a number)
40. About how many total parts did your shop finish in 2016? (Enter a number without commas)
41. About how many different parts did your shop finish in 2016? (Enter a number without commas)
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Profile Questions
2017 Products Finishing Top Shops Benchmarking Survey
Please rate each item in the questions that follow in the interest of data quality and to receive the report.
42. Which of the following industries does your business primarily serve? (Select ALL that apply)
Aerospace
Agriculture/construction equipment
Appliances
Automotive
Building construction
Electronics, computers
Fasteners
Furniture manufacturing
Hardware/tools
Machinery/industrial
Medical
Military/government
Oil & gas mining
Power generation (turbines, batteries)
Pumps, valves & plumbing
Wire goods/pipes
Other (please list)
43. Which certifications, if any, does your finishing shop currently have? (Select ALL that apply)
AAMA 2603
AAMA 2604
AAMA 2505
API Q1
ISO9901
NADCAP
PCI 3000/4000
None of the above
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44. Which approvals does your finishing shop currently have? (Select ALL that apply)
Aerojet
BAE Systems
Bell Helicopter
BMW
Boeing
Caterpillar
Cessna Aircraft
Chrysler
Eaton Aerospace
Ford
GE
General Dynamics
GM
Goddard Space Flight (NASA)
Goodrich Aerospace
Honda
Honeywell
IBM
John Deere
Lockheed Martin
Lycoming/Textron
Martin Marietta
McDonnell Douglas
MD Helicopters
Mercury Marine
MOOG
Motorola
Nissan
Northrop Grumman
Pratt and Whitney
Raytheon
Rockwell-Collins
Rolls Royce Corp.
Sikorsky Aircraft
Tacom
Toyota
United Technologies
None of the above
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Finishing Technology
2017 Products Finishing Top Shops Benchmarking Survey
45. Which of the following finishing surfaces accounts for at least 20% of your total processes on its own?(Select ALL that apply)
Aluminum surfaces
Steel surfaces
Wood or MDF surfaces
Plastic surfaces
None of the above
46. Which additional types of finishing operations does your shop perform? (Select ALL that apply)
Abrasive Blasting
Mass Finishing
Plating
Polishing or Buffing
Printed Circuit Boards
Spray Painting
Vacuum Coating
None of the above
47. Which types of inspection equipment does your shop offer? (Select ALL that apply)
Adhesion
Appearance
Coating Thickness
Color and Gloss
Corrosion Resistance
Cure
Customer Specific
Dimensional
Filters
Hydrogen Embrittlement
Salt Spray
Torque Tension
Water Immersion
Wet Analysis
Viscosity
None of the above
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Software
2017 Products Finishing Top Shops Benchmarking Survey
48. What lab analysis software does your shop use to provide support for statistical process control?(Select ALL that apply)
Scheduling and tracking of analysis events
Statistics and trend charts
Event logs and reports
Required corrective actions tracked
Solution adjustment/add slips
None of the above
49. Besides lab software, which other types of computer software does your shop use? (Select ALL thatapply)
Automated process lines
Localized PDA devices for manual process
Process tank sensors
Track product quality and defects
Continuous-process improvement programs
Process monitoring
None of the above
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Training and Human Resources
2017 Products Finishing Top Shops Benchmarking Survey
You may need to refer to company data to answer the following questions. Please take the time to do so in the interest of data qualityand to receive the report.
50. How many people did your shop employ in 2016? (Please enter a number; decimals, symbols, andwords are not accepted.)
51. Do you plan to increase, decrease or keep the same the number of employees in 2017? (Select ONEresponse)
Increase
Decrease
Keep the same
52. What was your shop's annual labor turnover rate in 2016? (As a percentage: number of voluntary plusinvoluntary separations/typical number of total staff. Please enter a number; symbols and words are notaccepted.)
53. What was your shop's accident incident rate in 2016? (As a percentage: number of accidentincidents/typical number of total staff. Please enter a number; symbols and words are not accepted.)
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54. What was the average hourly wage rate, to the nearest dollar and without overtime, for shop floorpersonnel in 2016? (Please enter a number, rounding to the nearest dollar; decimals, words and symbolsare not accepted)
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Training and Human Resources
2017 Products Finishing Top Shops Benchmarking Survey
55. Which human resource practices/programs did your business use in 2016? (Select ALL that apply)
Annual review and raise program
Apprenticeship program
Bonus plan
Education reimbursements
Employee ownership options
Formal employee training programs
Formal safety/health program
Leader/supervisor development
Paid medical benefits
Profit- or revenue-sharing plan
Teaming/team-building practices
None of the above
56. On average, how many hours of formal training did each full-time employee receive in 2016? (SelectONE response)
Less than 8 hours
8 - 20 hours
21 - 40 hours
More than 40 hours
Thank you for your time!
If you completed the survey on paper rather than online, please return it by June 1, 2017, by mailing it to:Products Finishing Magazine, Attn: Tim Pennington. Editor, 6915 Valley Avenue, Cincinnati, OH 45244.or by faxing it to: 513-527-8801.
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