A playbook with 47 detailed analyses for a manufacturing company
Each analysis includes:
- Goal of the analysis
- Data required
- Detailed step-by-step instruction on how to conduct the analysis
- Format of the output of analysis
- How to interpret results
- Steps a company can take to improve on the measure
In this guide you'll learn the following 47 analyses across seven categories:
Table of Contents
A. OPERATIONS
- Capacity Utilization Analysis
- Operational Efficiency (OEE) Analysis
- Supply Chain and Logistics Optimization
- Production Lead Time Analysis
- Lean Manufacturing and Waste Reduction Assessment
- Inventory Turnover and Management Efficiency
- Quality Control and Defect Rate Analysis
- Capacity Expansion and Flexibility Assessment
- Maintenance Strategy and Downtime Analysis
- Factory Layout and Process Flow Optimization
- Throughput and Bottleneck Identification
- Production Scheduling and Demand Alignment
- Process Standardization and Replication Across Plants
- Work-in-Progress (WIP) Inventory Management
- Material Handling and Internal Logistics Efficiency
- Finished Goods Storage and Warehousing Optimization
- Capacity Buffers and Flexibility in Response to Demand Fluctuations
B. SUPPLY CHAIN & PROCUREMENT
- Bill of Materials (BOM) and Cost Structure Analysis
- Supplier Risk and Dependency Analysis
- Supplier Quality Management
- Raw Material Sourcing and Procurement Efficiency
- Vendor-Managed Inventory (VMI) Program Evaluation
- In-house Production vs. Outsourcing Feasibility
C. TECHNOLOGY & AUTOMATION
- Automation and Technology Integration Analysis
- Factory Automation Level and Robotics Utilization
- Tooling and Machine Setup Time Optimization
- Equipment Downtime Tracking and Root Cause Analysis
- Spare Parts Management and Predictive Maintenance Systems
- Manufacturing Cycle Time Reduction
- Energy Consumption and Efficiency Analysis
D. FINANCE & ASSET MANAGEMENT
- Capital Expenditure (CapEx) Effectiveness in Equipment and Technology
- Cost of Goods Sold (COGS) Breakdown and Margins Analysis
- Asset Utilization and Lifecycle Management
- Return on Invested Capital (ROIC) for Manufacturing Assets
- Working Capital Management in Manufacturing
E. PRODUCT & PROCESS DEVELOPMENT
- Product Customization and Modularity Assessment
- New Product Introduction (NPI) and Time-to-Market Evaluation
- Custom Manufacturing vs. Mass Production Analysis
- Product Yield and Scrap Rate Analysis
- Make-to-Stock vs. Make-to-Order Strategy Evaluation
F. ENVIRONMENTAL & SUSTAINABILITY
- Sustainability and Environmental Impact Analysis
- Heat, Water, and Waste Management in Production
- Environmental Compliance and Emissions Reduction Strategies
- Reverse Logistics and Product Lifecycle Management
G. LOGISTICS & AFTERMARKET SERVICES
- Aftermarket Services and Spare Parts Logistics
- Multi-Site Manufacturing Network Optimization
- Safety and Compliance Audit