Annual manufacturing study measures differences between U.S., international plants
Study finds International plants spent significantly more on capital upgrades than U.S.-based facilities, U.S. plants will continue to lag on spending for capital improvements
Although manufacturing plants around the world continue to operate well below capacity, nearly half of them plan to increase spending on capital equipment in the coming year.
International plants spent significantly more on capital upgrades than U.S.-based facilities in the past year – 10 percent of plant revenue (median) compared to 3.1 percent (median) at U.S. plants. Further, the spending gap looks to continue through 2011, with 55 percent of international plants planning to increase capital spending, compared to 44 percent of U.S. plants.
The data comes from the just-released MPI Manufacturing Study, and is highlighted in the Manufacturing 2010/2011 Executive Summary. The annual study — the most comprehensive annual survey of manufacturing performance data in the world — helps organizations to benchmark operations and find out how top-performers are achieving world-class results.
Founded in 1997, the study this year includes a comparison of U.S. facilities (334 plants) vs. plants from around the world (145 plants) — vital in an era of increasingly global competition.
“This year we were able to increase the international sampling to allow comparisons between metrics in the U.S. and elsewhere,” said John Brandt, CEO of The MPI Group. “Executives want to benchmark against the best performances and best practices around the world — not just in the United States. We’re delighted to offer these hard-to-get metrics.”
The study was conducted with support from Thomas International Publishing Co. and includes detailed information on practices and performance metrics for:
- Human resources measures, such as annual labor turnover rates.
- Operations ratios, such as sales per employee.
- Supply chain metrics, such as customer retention rates.
- Capacity/equipment/investment benchmarks, such as machine availability.
- Green/sustainability targets, such as percentage of recyclable/reusable products.
“There are hundreds of insights in the overall study findings, and the data also can be viewed on an industry-by-industry basis,” Brandt said. “There’s no substitute for competitive intelligence — and the Manufacturing Study offers a clear view of what it takes to survive and thrive in a challenging global environment.”
Here are the various formats in which the study is presented:
- Manufacturing 2010/2011 Executive Summary: 28 pp., immediate download
- 2010/2011 Manufacturers Data Report: 250+ plus pp., immediate download
- 2010/2011 Global Benchmarking Toolkit: Online/interactive
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2012 Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.