Mastering manufacturing excellence: The role of benchmarking and best practices

In the fast-paced world of manufacturing, staying ahead of the competition requires more than just cutting-edge technology and efficient processes.

One strategy that often sets successful manufacturing companies apart is benchmarking. It allows companies to measure their performance against industry standards and paves the way for continuous improvement.

What is benchmarking for manufacturing companies, and why is it important?

Benchmarking is more than just a tool. It drives manufacturers toward sustained success. At its core, benchmarking is measuring an organization’s performance against predefined standards, or benchmarks. For manufacturing companies, these benchmarks encompass a wide range of metrics, from production output and quality to resource utilization and customer satisfaction.

By comparing these metrics with industry norms and best practices, companies can identify areas for improvement and set realistic goals for growth. By implementing periodical benchmarking exercises, a company can establish a consistent feedback loop by which they operate their business and make critical decisions against.

How can benchmarking help?

• Identifying improvement opportunities: By comparing a company’s performance against industry leaders, you can uncover where processes, quality or efficiency can be improved.
• Setting realistic goals: Benchmarking helps set achievable goals based on industry standards, helping ensure that a company’s growth trajectory is practical.
• Learning from the best: Studying successful companies provides valuable insights into the strategies and practices that lead to excellence. This knowledge can be adapted to suit a company’s unique strategies.
• Enhancing competitive edge: Benchmarking fosters innovation by encouraging companies to adopt cutting-edge technologies and best practices, staying ahead of competitors.

The four key areas of focus for benchmarking

Benchmarking isn’t a one-size-fits-all approach; it encompasses multiple dimensions of a manufacturing business and the underlying philosophy of the manufacturing environment. For instance, in lean manufacturing, benchmarking is integral to the pursuit of continuous improvement. It involves comparing processes and practices against lean principles to identify waste and inefficiencies. This practice empowers companies to embrace lean thinking and optimize operations.

Regardless of the types of manufacturers we work with, the key aspects of benchmarking that we assess are broadly categorized into four key areas:

• Operational efficiency: Streamlining production processes, reducing waste and optimizing resource allocation are crucial factors in achieving operational excellence. Benchmarking against industry leaders can reveal opportunities to enhance efficiency and cut costs.
• Quality and defect reduction: Maintaining high-quality products while minimizing defects is a foundation of manufacturing success. Benchmarking against companies known for exceptional quality control can shed light on strategies to achieve zero defect production.
• Supply chain management: A well-managed, flexible supply chain helps ensures timely delivery of raw materials and components, minimizing disruptions and delays. Benchmarking supply chain practices can lead to a more resilient and responsive network.
• Innovation and adoption: Manufacturing is rapidly evolving with advancements in technology. Benchmarking in this area helps companies assess their adoption of innovative tools and processes, allowing them to stay competitive in their dynamic, ever-changing industry.

How to benchmark a company

When it comes to measuring your business against the best in your industry, the process of benchmarking a company involves several steps:

• Identify metrics and goals: Create targeted and specific questions that help define the metrics to benchmark against and the goals to achieve — making sure they align with a business strategy. These can range from improving production yield to reducing lead times.
• Document current processes: Outline current process to more easily identify steps that may need improvement or elimination later in the benchmarking process.
• Gather data: Collect relevant data from their company and external sources. This data will serve as the basis for comparison.
• Look at trends: Analyze any current trends in the industry, including how fast it is advancing. Consider the impact of these and how they can be used in forecasting to keep the business in line with the direction of the industry.
• Select benchmarks: Identify other companies in the industry that excel in the areas being examined. These companies serve as the benchmarks.
• Analyze and compare: Compare their company’s performance with that of the benchmark companies. This analysis helps identify gaps and areas for improvement.
• Implement improvements: Based on the analysis and business strategy, develop and implement strategies to bridge the performance gaps. Make sure these goals are concrete, attainable and timely. These could involve process changes, technology adoption or operational adjustments.
• Monitor progress: Continuously monitor the company’s progress and adjust strategies as needed. Benchmarking is an ongoing process that requires adaptation and refinement.

Best practices for benchmarking

Pinpointing which metrics, companies and industry standards to benchmark against is a tricky problem, but a worthwhile pursuit. To make the most of benchmarking, a company should implement these best practices:

• Choose relevant metrics: Select metrics that align with the company’s strategy. Avoid the temptation to benchmark everything. Focus on what truly matters.
• Ensure data accuracy: Reliable data is the foundation of effective benchmarking. Ensure the data collection methods are accurate and consistent.
• Adapt, don't copy: Benchmarking is about learning, not replication. Adapt successful strategies to suit a company’s unique circumstances.
• Involve stakeholders: Collaborate with employees at all levels to gain a holistic view of processes and identify improvement opportunities.
• Be open to change: Benchmarking might reveal uncomfortable truths. Embrace change and view it as an opportunity for growth.
• Start early: To be the best and stay ahead of competition, start benchmarking as early as possible. Benchmarking provides the “where” and “how” to improve business. The sooner they are known, the sooner a company can shift from reactive to flexible and strategic.

How Wipfli can help

In manufacturing, benchmarking can fuel progress and guide businesses toward sustained success. Our team of experienced professionals understands the need for continued improvement, and we have the expertise necessary to set your organization on the path to growth. Learn more about how our strategy and operations services can help optimize your business and maximize your potential.