Manufacturing Health Check

If you would like to see your business DNA please feel free to complete this survey. We will e-mail your organisation summary DNA profile to you within 24 hours.

Q1 - How often do you have customer returns as a result of poor quality ?*
- At least once per day
- At least once per week
- At least once per month
- Rarely
- Never
Q2 - How often do you fail to deliver your customer requirement ?*
- At least once per day
- At least once per week
- At least once per month
- Rarely
- Never
Q3 - What is your No 1 critical success factor ?*
- Quality
- Cost
- Delivery
- Service
- Unique product
Q4 - Who decides what products to develop ?*
- Your Head office
- Managing Director
- Design team
- Market analysis
- Your main customer(s)
Q5 - If it is decided to update your product range, what is your biggest consideration ?*
- Large scale capital equipment spend
- Major tooling spend
- Availability of skilled labour
- Change in marketing and selling direction
- No major considerations
Q6 - What is your normal time to market for a new product ?*
- Up to 3 months
- 3 to 6 months
- 6 months to 1 year
- 1 to 2 years
- Greater than 2 years
Q7 - Who in your business looks at customer satisfaction results on a daily basis ?*
- Managing Director
- Sales Management
- Operations Mangement
- All or most employees
- Not reviewed on a daily basis
Q8 - How often is a new idea from the shopfloor implemented ?*
- Regularly through employee suggestion schemes and works council etc
- 1 or 2 ideas implemented on an annual basis from employee feedback schemes
- Occasionally on an adhoc basis
- Never, ideas are put forward but have not been adopted as yet
- Never, there are no ideas coming from the shopfloor
Q9 - How are employees informed of any major company developments ?*
- Not communicated
- Notice boards and/or mass letter outlining specific developments
- Works council or union representatives
- Employee briefings or regular team cascade meetings
- 2 or more of the above items (excluding no communication)
Q10 - How do management receive feedback from employees ?*
- No official communication channels
- Annual performance review
- Regular works council or union meetings
- Regular Q&A sessions between managers and all employees
- A combination of the above (excluding no communication)
Q11 - Who regularly checks operators standard work ?*
- Not checked regularly
- Their immediate Team Leader or equivalent
- Their section Supervisor
- Their area Manager
- Senior Management
Q12 - How regularly is operators standard work checked ?*
- Don't have standard work
- Once every hour
- Once every shift
- Once every week
- Ad hoc checks carried out
Q13 - How would you descibe your company leadership style ?*
- I'm the boss so do it my way
- System says do it this way
- Use the organisation structure with each level explaining their decision where possible
- Set boundaries and allow your people to make decisions within these defined boundaries
- Give your people free rein
Q14 - Are your company goals well defined and understood by your people ?*
- No defined goals
- Goals change on a regular basis
- Goals are defined but not communicated
- Goals understood by senior management
- Goals are regularly communicated and reinforced
Q15 - How are tasks completed in your business ?*
- Tasks are regularly completed by area managers
- Tasks are completed by whoever is available and/or willing
- Staff regularly ask for their work to be checked
- Task ownership in most cases defined but not always carried out to standard
- Tasks have clearly defined responsibility and are normally carried out to the standard
Q16 - What standards do you have in your business ?*
- No documented standards
- Just safety and/or environmental standards
- Just operator work instructions
- Just quality standards
- All or most of the above (excluding no standards)
Q17 - Do your employees understand the customer specification ?*
- There are no formal company standards
- Company standards are not linked to the customer specification
- Company standards containing references to customer specification are developed during the production phase
- Company standards reflect the customer specification but are either not visible or visible but not used
- Company standards fully integrate the customer specification and are highly visible and utilised for training and production
Q18 - What is currently recognised as the biggest source of waste in your business ?*
- No major waste
- Company structure
- Excessive overtime and/or scrap
- Over production
- Lots of different sources of waste
Q19 - What is the constraint in your business ?*
- No constraint
- The market
- The customer
- A Specific process
- The workforce
Q20 - How is your production plan generated ?*
- Fixed production plan based on production capacity
- Customer orders prioritised based on who shouts loudest
- Customer demand aggregated and managed using safety stock
- Cusomer demand matched on a weekly basis
- Heijunka system in place matched to daily customer demand on a JIT basis
Q21 - What is your company measure of productivity ?*
- No consistent productivity measure
- Production quantity per hour (or day)
- Production quantity per labour hour worked
- Value added time divided by total time
- Throughput per bottleneck unit
Q22 - What philosophy of business improvement do you follow ?*
- No system followed consistently
- Six Sigma followed consistently
- Theory of Constraints (TOC) followed consistently
- Lean / TPS followed consistently
- Own system adopted and followed consistently
Q23 - How many continuous improvement projects have been implemented in the last 12 months ?*
- None
- 1 Project
- 2 to 3
- 4 to 5
- More than 5
Q24 - Why did you visit Lean QCD's website ?*
- Looking for help on a specific subject
- Through social networking blogs and discussion points
- Recommendation
- Looking for training
- Looking for lean support
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