welcome to top shops plating & anodizing products ... · products finishing top shops 2020:...
TRANSCRIPT
Welcome to Top Shops
Products Finishing Top Shops 2020:Plating & Anodizing
Thank you for participating in the Products Finishing Top Shops Benchmarking Survey for plating andanodizing, which highlights the attributes shared by leading North American finishing operations. By fullycompleting this survey, you will receive a benchmarking report customized for your shop. This surveypertains to plating and anodizing, in particular. There is a separate survey for shops that perform liquid andpowder coating. Please proceed only if your shop does plating and/or anodizing.
Be assured that all responses are confidential to the staff of Products Finishing and will not be shared byany outside agency or organization.
This survey must be completed by January 10, 2020. If you need to gather data or you get interrupted, youmay close and return to the survey on this device as many times as you like until you select 'SubmitResponses' on the final page. It is important that you answer all of the questions in order to ensure dataquality and to receive your customized report. If you have questions, please contact Jan Schafer, Directorof Market Research, [email protected].
If you want to keep a record of your responses, we suggest you print a copy of each page with yourresponses before selecting 'next' to advance to the next page/question.
1. Does your shop currently perform plating and/or anodizing on your premises?*
Yes
No
1
Company & Contact Information
Products Finishing Top Shops 2020:Plating & Anodizing
Your Name:
Title:
Company Name:
Address:
City:
State: -- select state --
ZIP:
Country:
Company Website:
Company PhoneNumber:
2. Please provide the following information to receive your report and for us to contact Top Shops:
3. Please provide your email address:
Top Official's Name:
Top Official's Title:
Top Official's Email:
4. Who is your top company official?
2
Before we begin...
Products Finishing Top Shops 2020:Plating & Anodizing
Many of the survey questions refer to 'your shop' or 'your business,' and here's how we'd like you to thinkabout it...
If your company has more than one location, please answer all survey questions in terms of the scope forwhich you have the most access to operations and performance data. In some cases, that is multiplelocations combined. In other cases, it is just one location, often the location where the person completingthe survey works. Either is acceptable since questions are asked in ways that make data from all sizebusinesses comparable.
If, however, you have equal access to site-specific operations and performance data for more than onelocation, please answer the survey based on the one location that is most representative of your businessoverall. In other words, provide answers based on a 'typical' location rather than one that is particularlystrong or particularly weak.
Most important is that you be consistent throughout the survey as far as the location(s) to which yourresponses apply.
3
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
This section of the survey includes questions pertaining to product quality, shop efficiency, andpractices directly involved in finishing processes.
Please read the instructions at each question for the accepted format for entering your data. If you receivean error message, please check your response for the correct format. It is also possible your response isconsidered outside the reasonable range for that question.
Please be thinking of 2019 as you answer each question unless indicated otherwise.
5. Which of the following practices and improvement methodologies did your business utilize in 2019?(Select ALL that apply)
5S workplace organization
Agile manufacturing
Benchmarking
Cellular manufacturing
Continuous improvement program
Customer surveys
Just-in-time movement of materials
Kaizen events/blitzes
Kanban and pull systems
Overall Equipment Effectiveness (OEE)
Poka yoke (error prevention)
Quality certs (i.e. ISO, NADCAP, etc.)
Six Sigma
Theory of constraints
Total productive maintenance
Total quality management
Value-stream mapping
None of the above
4
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
6. What was your shop's order lead time in 2019, defined as the average number of days from receipt oforder to delivery to customer? Example: For 6 days, you would enter 6. For 6 1/2 days, you would enter 6.5.
7. What was your shop's on-time delivery rate in 2019, defined as the percentage of goods delivered on thetiming committed? Enter your number without a % sign. Example: For 80%, you would enter 80 without a decimal or % sign. For 80.5%, you would enter 80.5without the %.
8. What was your shop's finished product first-pass quality yield in 2019, defined as the percentage ofproducts passing inspection on the first attempt; i.e. no re-work was required? Enter your number without a% sign.Example: For 80%, you would enter 80 without a decimal or % sign. For 80.5%, you would enter 80.5without the %.
9. What was your shop's finishing usage in 2019, defined as the average number of hours finishingequipment is in production in a 24 hour day? Your answer should be between 1 and 24. Example: For 8 hours, you would enter 8. For 8 1/2 hours, you would enter 8.5.
10. How many shifts per day did your shop typically run in 2019?
5
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
Environmental management
Parts Inspection
Analytical testing
Hazardous waste management
Training
11. Please estimate the average number of labor-hours your shop as a whole spent in total each week oneach of the following tasks in 2019. Please round to the nearest whole number. Enter '0' if your shop does not perform the task.
Do not have written
proceduresHave written procedures,
but need updatingHave written procedures,
and they are current
Plating/finishing procedures
Bath quality/performance
Preventative maintenance
Waste treatment equipment operation/maintenance
Hazardous waste management
Hazardous material handling/spill response
12. Please select the rating that best describes your 2019 business practice in each of the areas listedbelow. (Select ONE rating for EACH row)
6
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
No records
are keptRecords are kept, but not analyzed
Records are kept and analyzed
Bath chemistry (analytical)
Bath chemical additions
Bath temperature
Rectifier use
Preventative maintenance logs
City water chemistry (e.g. hardness)
Electricity use
Treatment sludge generation
Waste treatment chemical reagent use
Water use
13. Please select the rating that best describes your shop's business practice in each of the areas listedbelow. Select ONE rating for EACH row.
7
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
14. Which of the following finishing operations did your shop perform in 2019? (Select ALL)
Anodizing Hardcoat
Anodizing Sulfuric
Black Chrome
Blackening/Antiquing
Black Nickel
Black Oxide
Brass
Bronze
Bronze, White
Cadmium
Chromate
Chrome, Decorative
Chrome, Hard
Copper
Gold
Nickel, Chrome
Nickel, Decorative
Nickel, Electroless
Nickel, Industrial
Passivation
Phosphating
Pickling
Plating on Plastic
PVD
Rhodium
Silver
Tin
Tin-Lead
Tin-Nickel
Zinc
Zinc/Cobalt
Zinc/Iron
Zinc/Nickel
Zinc/Tin
None of the above
8
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
15. Which finishing operations account for most of your shop's total processes? Select up to 3.
Anodizing Hardcoat
Anodizing Sulfuric
Black Chrome
Blackening/Antiquing
Black Nickel
Black Oxide
Brass
Bronze
Bronze, White
Cadmium
Chromate
Chrome, Decorative
Chrome, Hard
Copper
Gold
Nickel, Chrome
Nickel, Decorative
Nickel, Electroless
Nickel, Industrial
Passivation
Phosphating
Pickling
Plating on Plastic
PVD
9
Rhodium
Silver
Tin
Tin-Lead
Tin-Nickel
Zinc
Zinc/Cobalt
Zinc/Iron
Zinc/Nickel
Zinc/Tin
10
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
16. Which additional types of finishing operations did your shop perform in 2019? (Select ALL that apply)
Abrasive blasting
Brush plating
Chemical milling
Electrocoating
Electroforming
Electropolishing
Etching
Lacquering
Mass finishing
Mechanical plating
Polishing or buffing
Powder coating
Printed circuit boards
Solid film lubricants
Spray painting
PVD
None of the above
11
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
17. Which types of inspection processes did your shop perform during the finishing process in2019? (Select ALL that apply)
Abrasion testing
Adhesion testing
Analytical chemistry
Atomic absorption analysis
Coating weight thickness testing
Continuity testing
Copper sulfate testing
Eddy current testing
Hardness testing
Humidity testing
Hydrogen embrittlement
Plating thickness
Porosity testing
Quench testing
Salt spray
Scanning electron microscope
Solderability testing
Solution analysis
Stress relief
Water immersion
X-ray thickness testing
XRF reading
None of the above
12
18. Which types of inspection processes did your shop perform after the finishing process in 2019? (SelectALL that apply)
Abrasion testing
Adhesion testing
Analytical chemistry
Atomic absorption analysis
Coating weight thickness testing
Continuity testing
Copper sulfate testing
Eddy current testing
Hardness testing
Humidity testing
Hydrogen embrittlement
Plating thickness
Porosity testing
Quench testing
Salt spray
Scanning electron microscope
Solderability testing
Solution analysis
Stress relief
Water immersion
X-ray thickness testing
XRF reading
None of the above
13
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
19. Which types of automation did your shop use in 2019? (Select ALL that apply)
Automated process lines
Process tank sensors
Track product quality and defects
Process monitoring
None of the above
14
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
20. Which types of pretreatment did your shop use in 2019? (Select ALL that apply)
Solvent wipe
Blasting
Aqueous - zinc phosphate
Aqueous - iron phosphate
Aqueous - nano technology
Other
None
21. Which types of racking did your shop use in 2019? (Select ALL that apply)
Hook
Custom - built in-house
Custom - outsourced
22. Which stripping practices did your shop use in 2019? (Select ALL that apply)
Burn off – oven
Fluidized sand stripping
Chemical stripping
Water blast
Grinding
Other
23. Which curing methods did your shop use in 2019? (Select ALL that apply)
Infrared
Convection
Electric heat
Natural gas heat
Other
None
15
Finishing Practices
Products Finishing Top Shops 2020:Plating & Anodizing
Weekly or more Monthly Quarterly Every 6 months Once
Ovens
Guages
Inspection
24. About how often did your shop calibrate equipment in 2019? (Select ONE per row)
25. Did your shop have onsite an environmental room with temperature and humidity control in 2019?
Yes
No
Built in-house Purchased
Do not have this software
Preventative maintenance
Order management
Quality assurance
26. Please indicate how, if at all, your shop acquired software for the purposes listed below. (Select ONEper row)
16
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
This section of the survey includes questions pertaining to financial, operational and customerinformation.
Products Finishing is looking to take Top Shops analysis to the next level by determining the key drivers ofrevenue and profit margin. To do this, we will correlate all the data within the survey – both the numericaldata and answers to the yes/no and select-all questions – with revenue and profit margin. We can only runthese correlations and determine the key drivers of revenue and profit margin if you all answer all of theseimportant financial questions.
Note these measures are designed to allow comparisons across shops without having to disclose specificfinancials. Be assured that all responses are confidential to the staff of Products Finishing and will not beshared by any outside agency or organization.
Please read the instructions at each question for the accepted format for entering your data. If you receivean error message, please check for the correct format. It is also possible your response is consideredoutside the reasonable range for that question.
27. Please provide your shop's 2019 gross sales per finishing line in dollars. Example: If your gross sales were $5000 and you have 2 lines, you would enter 2500. Please round to thenearest whole number and enter without any signs or symbols.
28. Please provide your shop's 2019 gross sales per employee in dollars. Example: If your gross sales were $5000 and you have 20 employees, you would enter 250. Please roundto the nearest whole number and enter without any signs or symbols.
29. Were any capital investments made in equipment for your shop in 2019? (Select ONE only)
Yes
No
Not sure
17
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
If you receive an error message, please check for the correct format. It is also possible yourresponse is considered outside the reasonable range for that question.
30. Please provide your shop's 2019 capital equipment expenditure as a percentage of gross sales. Roundto the nearest whole number and enter without a % sign. Formula = (2019 cap equip exp / 2019 gross sales) * 100 Example: If your capital equipment expenditure were $500 and your gross sales were $5000, youwould enter 10. You may enter decimals but no other signs or symbols.
31. Please provide your shop's percent change in annual sales from 2018 to 2019 using the followingformula. Round to the nearest whole number, using a minus sign if necessary. Formula = [(2019 gross sales - 2018 gross sales) / 2018 gross sales] * 100Example: If your 2019 sales were $5000 and your 2018 sales were $4000, you would enter 25.
32. Please estimate your shop's percent change in annual sales from 2019 to 2020. Round to the nearestwhole number, using a minus sign if necessary. Formula = [(2020 estimated sales - 2019 gross sales) / 2019 gross sales] * 100Example: If your estimated 2020 sales are $4000 and your 2019 sales were $5000, you would enter -20.
18
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
33. Please provide your shop's 2019 net income relative to gross sales, rounded to the nearest wholenumber. Include a minus sign if your number is negative.Formula = [(2019 net income / 2019 gross sales)*100] Example: If your 2019 net income were negative $300 and your gross sales were $5000, you would enter -6.
34. Please provide your shop's 2019 net income relative to total assets, rounded to the nearest wholenumber. This is ROA on your shop's balance sheet. Include a minus sign if your number is negative.Formula = [(2019 net income / 2019 total assets) * 100] Example: If your 2019 net income was negative $300 and your total assets were $10,000, you would enter-3.
35. There is no single formula that fits how every shop figures capacity utilization. For this question, thinkabout what you consider to be at full capacity for your shop. Then enter as a percentage the degree towhich your shop’s total capacity was typically in use in 2019. Example: If 85% of your shop’s total capacity was typically in use in 2019, meaning you typically had 15%capacity to spare, you would enter 85 for capacity utilization.
36. Please provide your shop's 2019 overall profit margin percentage. Enter your number without a % sign. You may enter decimals but no other signs or symbols.
19
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
37. Please provide your shop's total revenue for 2019.Round to the nearest whole number and enter without any signs or symbols.
Plating
Anodizing
38. What percentage of your shop's 2019 total revenue came from each process?Please round each percentage to a whole number and enter without a % sign. Your percentages must sumto 100.
Functional
Decorative
39. What percentage of your shop's 2019 total revenue came from each type of finishing?Please round each percentage to a whole number and enter without a % sign. Your percentages must sumto 100.
20
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
40. Which of the following supply chain practices did your shop use in 2019? (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
41. Which of the following marketing tools did your business use in 2019? (Select ALL that apply)
Blogs
Brochures/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
YouTube
None of the above
21
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
Please provide the following measures for your business for 2019. Note these measures aredesigned to allow important comparisons across shops without having to disclose specificfinancials. If you receive an error message, please check for the correct format. It is also possibleyour response is considered outside the reasonable range for that question.
42. How many active customers did your business have in 2019?
43. What was your shop's customer retention rate for 2019? This is the number of your shop's customers in2019, who were also customers in 2018, as a percentage of your total 2018 customer base. Enter yournumber without a % sign.Example: If you had 50 customers in 2019 who were also customers in 2018, and a total of 60 customersin 2018, your customer retention rate would be 83%, and you would enter 83. You may enter decimals butno other signs or symbols. For numbers less than 1%, please round to 1.
44. What percentage of new business quoted in 2019 was actually booked? Enter your number without a %sign.Example: if you quoted 80 new jobs in 2019 and booked 40, you would enter 50. You may enter decimalsbut no other signs or symbols.
22
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
Plating
Anodizing
45. How much did your shop spend in dollars on materials for each of these processes in 2019?Please enter numbers only, rounding to the nearest whole number; decimals, symbols and words are notaccepted.
Automated or Manual Plating Line
Poly Tanks/Liners
Steel Tanks/Liners
Racking
Barrels/Baskets
Auxiliary equipment (pumps, ovens, power supplies, etc.)
Plating chemistries
Pretreatment processes
46. How much do you estimate your shop will spend, in dollars, to make purchases in thesecategories in 2020? Enter '0' if you expect to make no investment in a category in 2020. Please enter numbers only, rounding tothe nearest dollar; decimals, symbols and words are not accepted.
23
Business Strategy
Products Finishing Top Shops 2020:Plating & Anodizing
47. What coating or services would you like to add to your shop in 2020? (Select ALL that apply)
Anodizing Hardcoat
Anodizing Sulfuric
Black Chrome
Blackening/Antiquing
Black Nickel
Black Oxide
Brass
Bronze
Bronze, White
Cadmium
Chromate
Chrome, Decorative
Chrome, Hard
Copper
Gold
Nickel, Chrome
Nickel, Decorative
Nickel, Electroless
Nickel, Industrial
Passivation
Phosphating
Pickling
Plating on Plastic
PVD
Rhodium
Silver
Tin
Tin-Lead
Tin-Nickel
Zinc
Zinc/Cobalt
Zinc/Iron
Zinc/Nickel
Zinc/Tin
None of the above
24
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
This section of the survey includes questions pertaining to the general characteristics that helpdefine your shop.
48. Which category best describes your shop's relation to its customer base? (Select ONE only)
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)
49. Which of the following best describes your shop's business? (Select ONE only)
High mix/low volume
High mix/high volume
Low mix/low volume
Low mix/high volume
50. Which statement best describes your shop's pricing strategy relative to competition? (Select ONE only)
Among the highest priced
Higher priced than average, but not among the highest
Priced about average
Lower priced than average, but not among the lowest
Among the lowest priced
25
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
You may need to refer to company data to answer the following questions. Please take the time todo so in the interest of data quality and to receive the report.
51. As of the end of 2019, about how many years will your shop have been in business? Please round to the nearest whole number.
52. About how many total parts did your shop finish in 2019? Please enter a whole number only; no commas or other symbols.
53. About how many different types of parts/SKU's did your shop finish in 2019? Please enter a whole number only; no commas or other symbols.
26
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
Plating
Anodizing
54. Switching gears a bit and now thinking about your shop’s finishing lines, how many lines were inproduction for each process in 2019? Please enter whole numbers only; no commas or other symbols.
Plating
Anodizing
55. How many lines of each type, if any, did your shop add in 2019?
27
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
56. Which of the following industries does your shop typically serve? (Select ALL that apply)
Aerospace
Agriculture/construction equipment
Appliances
Automotive
Architectural 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 specify)
28
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
57. Which of the industries served do you typically consider THE PRIMARY contributors to your shop'sbusiness? (Select up to 5)
Aerospace
Agriculture/construction equipment
Appliances
Automotive
Architectural 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
[Insert text from Other]
29
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
58. Which certifications, if any, does your finishing shop have currently? (Select ALL that apply)
ISO 9001
ISO 13485
ISO 16949
AS9100
NADCAP
None of the above
Other (please specify)
59. Of which trade associations was your shop a member in 2019? (Select ALL that apply)
Aluminum Anodizers Council (AAC)
National Association for Surface Finishers (NASF)
30
Shop Profile
Products Finishing Top Shops 2020:Plating & Anodizing
60. Which approvals did your finishing shop hold in 2019? (Select ALL that apply)
Aerojet
BAE Systems
Bell
BMW
Boeing
Caterpillar
Cessna Aircraft
Chrysler
Eaton Aerospace
Ford
GE
General Dynamics
GM
Goddard Space Flight (NASA)
Honda
Honeywell
IBM
John Deere
Lockheed Martin
Lycoming/Textron
Martin Marietta
MD Helicopters
Mercury Marine
MOOG
Motorola
Nissan
Northrop Grumman
Raytheon
Rolls Royce Corp.
Sikorsky Aircraft
Toyota
United Technologies
None of the above
Other (please specify)
31
Training and Human Resources
Products Finishing Top Shops 2020:Plating & Anodizing
This section of the survey pertains to employees, training, and shop safety.
61. How many total people did your shop employ in 2019 at the location(s) your answers pertain to?
62. How many employees at this location were shop floor employees in 2019?
63. How many employees at this location were Certified Electroplater Finishers (CEF) in 2019?
32
Training and Human Resources
Products Finishing Top Shops 2020:Plating & Anodizing
64. Thinking of the total number of employees at this location, do you plan to increase, decrease, or keepthe same number of employees in 2020? (Select ONE only)
Increase
Decrease
Keep the same
65. What was your shop's annual labor turnover rate for all shop floor employees in 2019? This is thenumber of voluntary plus involuntary separations of shop floor employees as a percentage of the usualtotal number of shop floor employees. Enter your number between 0 and 100 without a % sign.You may enter decimals but no other signs or symbols. Example: If 6 shop floor employees left in 2019 and your usual shop floor staff totals 30, you would enter20.
66. Did your shop have any accident incidents in 2019? (Select ONE only)
Yes
No
Not Sure
33
Training and Human Resources
Products Finishing Top Shops 2020:Plating & Anodizing
67. What was your shop's annual accident incident rate for shop floor employees in 2019? This is thenumber of shop floor accident incidents as a percentage of the typical number of shop floor staff. Enteryour number without a % sign.Example: if you had 2 accident incidents in 2019 and your shop floor staff typically totals 30, you wouldenter 6.67. You may enter decimals but no % sign.
68. Which of the following designated safety roles did your shop have in place in 2019?
Safety manager
Safety committee
None of these
69. What was your shop's insurance Experience Modification Rate (EMR) for 2019?
34
Training and Human Resources
Products Finishing Top Shops 2020:Plating & Anodizing
70. What was the average hourly wage rate for hourly paid, non-management shop floor personnel in2019 excluding overtime? Please enter a number. You may enter decimals but no other signs or symbols.
71. Which human resource practices/programs did your business use in 2019? (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
72. Were any of your shop's employees part of a union in 2019?
Yes
No
35
Products Finishing Top Shops 2020:Plating & Anodizing
This is the final page of the survey. Please double-check your responses for accuracy and completenessbefore you continue.
Once you click Submit Responses on this page, you will be taken to the Products Finishing website. Yoursurvey will be locked and submitted and you will not be able to change any of your answers. Before youclick Submit Responses, you may close and return to the survey on this device to make changes asmany times as you like until the deadline on January 10, 2020.
36