liquid and powder coatings, electrocoat 2017 products ...will also be profiled in an upcoming issue...

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


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


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


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


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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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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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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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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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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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


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


29. Abrasive Blast Process

Incoming part assessment

Abrasive media flow

Nozzle air pressure

Dwell time

Dust collector efficiency/air flow

Working mix

Surface cleanliness


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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


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Monitoring Practices


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


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


33. Primer

Incoming parts inspected

Booth balance


Film thickness

Atomizer parameters set


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34. Basecoat


Flashtimes set



Film builds


35. Clearcoat


Flashtimes set



Cure


36. Final Part Inspection

Inspection criteria posted

Adequate lighting

Defects tracked

FTT monitored

Scrap and repaints tracked


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Profile Questions


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)


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


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


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


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



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


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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liquid and powder coatings, electrocoat 2017 products ...will also be profiled in an upcoming issue...

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