welcome to top shops plating & anodizing products ... · products finishing top shops 2020:...

Welcome to Top Shops

Products Finishing Top Shops 2020:Plating & Anodizing

Thank you for participating in the Products Finishing Top Shops Benchmarking Survey for plating andanodizing, which highlights the attributes shared by leading North American finishing operations. By fullycompleting this survey, you will receive a benchmarking report customized for your shop. This surveypertains to plating and anodizing, in particular. There is a separate survey for shops that perform liquid andpowder coating. Please proceed only if your shop does plating and/or anodizing.

Be assured that all responses are confidential to the staff of Products Finishing and will not be shared byany outside agency or organization.

This survey must be completed by January 10, 2020. If you need to gather data or you get interrupted, youmay close and return to the survey on this device as many times as you like until you select 'SubmitResponses' on the final page. It is important that you answer all of the questions in order to ensure dataquality and to receive your customized report. If you have questions, please contact Jan Schafer, Directorof Market Research, [email protected].

If you want to keep a record of your responses, we suggest you print a copy of each page with yourresponses before selecting 'next' to advance to the next page/question.

1. Does your shop currently perform plating and/or anodizing on your premises?*

Yes

No

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mailto:[email protected]

Company & Contact Information


Your Name:

Title:

Company Name:

Address:

City:

State: -- select state --

ZIP:

Country:

Company Website:

Company PhoneNumber:

2. Please provide the following information to receive your report and for us to contact Top Shops:

3. Please provide your email address:

Top Official's Name:

Top Official's Title:

Top Official's Email:

4. Who is your top company official?

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Before we begin...


Many of the survey questions refer to 'your shop' or 'your business,' and here's how we'd like you to thinkabout it...

If your company has more than one location, please answer all survey questions in terms of the scope forwhich you have the most access to operations and performance data. In some cases, that is multiplelocations combined. In other cases, it is just one location, often the location where the person completingthe survey works. Either is acceptable since questions are asked in ways that make data from all sizebusinesses comparable.

If, however, you have equal access to site-specific operations and performance data for more than onelocation, please answer the survey based on the one location that is most representative of your businessoverall. In other words, provide answers based on a 'typical' location rather than one that is particularlystrong or particularly weak.

Most important is that you be consistent throughout the survey as far as the location(s) to which yourresponses apply.

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Finishing Practices


This section of the survey includes questions pertaining to product quality, shop efficiency, andpractices directly involved in finishing processes.

Please read the instructions at each question for the accepted format for entering your data. If you receivean error message, please check your response for the correct format. It is also possible your response isconsidered outside the reasonable range for that question.

Please be thinking of 2019 as you answer each question unless indicated otherwise.

5. Which of the following practices and improvement methodologies did your business utilize in 2019?(Select ALL that apply)

5S workplace organization

Agile manufacturing

Benchmarking

Cellular manufacturing

Continuous improvement program

Customer surveys

Just-in-time movement of materials

Kaizen events/blitzes

Kanban and pull systems

Overall Equipment Effectiveness (OEE)

Poka yoke (error prevention)

Quality certs (i.e. ISO, NADCAP, etc.)

Six Sigma

Theory of constraints

Total productive maintenance

Total quality management

Value-stream mapping

None of the above

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Finishing Practices


6. What was your shop's order lead time in 2019, defined as the average number of days from receipt oforder to delivery to customer? Example: For 6 days, you would enter 6. For 6 1/2 days, you would enter 6.5.

7. What was your shop's on-time delivery rate in 2019, defined as the percentage of goods delivered on thetiming committed? Enter your number without a % sign. Example: For 80%, you would enter 80 without a decimal or % sign. For 80.5%, you would enter 80.5without the %.

8. What was your shop's finished product first-pass quality yield in 2019, defined as the percentage ofproducts passing inspection on the first attempt; i.e. no re-work was required? Enter your number without a% sign.Example: For 80%, you would enter 80 without a decimal or % sign. For 80.5%, you would enter 80.5without the %.

9. What was your shop's finishing usage in 2019, defined as the average number of hours finishingequipment is in production in a 24 hour day? Your answer should be between 1 and 24. Example: For 8 hours, you would enter 8. For 8 1/2 hours, you would enter 8.5.

10. How many shifts per day did your shop typically run in 2019?

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Finishing Practices


Environmental management

Parts Inspection

Analytical testing

Hazardous waste management

Training

11. Please estimate the average number of labor-hours your shop as a whole spent in total each week oneach of the following tasks in 2019. Please round to the nearest whole number. Enter '0' if your shop does not perform the task.

Do not have written

proceduresHave written procedures,

but need updatingHave written procedures,

and they are current

Plating/finishing procedures

Bath quality/performance

Preventative maintenance

Waste treatment equipment operation/maintenance

Hazardous waste management

Hazardous material handling/spill response

12. Please select the rating that best describes your 2019 business practice in each of the areas listedbelow. (Select ONE rating for EACH row)

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Finishing Practices


No records

are keptRecords are kept, but not analyzed

Records are kept and analyzed

Bath chemistry (analytical)

Bath chemical additions

Bath temperature

Rectifier use

Preventative maintenance logs

City water chemistry (e.g. hardness)

Electricity use

Treatment sludge generation

Waste treatment chemical reagent use

Water use

13. Please select the rating that best describes your shop's business practice in each of the areas listedbelow. Select ONE rating for EACH row.

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Finishing Practices


14. Which of the following finishing operations did your shop perform in 2019? (Select ALL)

Anodizing Hardcoat

Anodizing Sulfuric

Black Chrome

Blackening/Antiquing

Black Nickel

Black Oxide

Brass

Bronze

Bronze, White

Cadmium

Chromate

Chrome, Decorative

Chrome, Hard

Copper

Gold

Nickel, Chrome

Nickel, Decorative

Nickel, Electroless

Nickel, Industrial

Passivation

Phosphating

Pickling

Plating on Plastic

PVD

Rhodium

Silver

Tin

Tin-Lead

Tin-Nickel

Zinc

Zinc/Cobalt

Zinc/Iron

Zinc/Nickel

Zinc/Tin

None of the above

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Finishing Practices


15. Which finishing operations account for most of your shop's total processes? Select up to 3.

Anodizing Hardcoat

Anodizing Sulfuric

Black Chrome


Black Nickel

Black Oxide

Brass

Bronze

Bronze, White

Cadmium

Chromate

Chrome, Decorative

Chrome, Hard

Copper

Gold

Nickel, Chrome

Nickel, Decorative

Nickel, Electroless

Nickel, Industrial

Passivation

Phosphating

Pickling

Plating on Plastic

PVD

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Rhodium

Silver

Tin

Tin-Lead

Tin-Nickel

Zinc

Zinc/Cobalt

Zinc/Iron

Zinc/Nickel

Zinc/Tin

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Finishing Practices


16. Which additional types of finishing operations did your shop perform in 2019? (Select ALL that apply)

Abrasive blasting

Brush plating

Chemical milling

Electrocoating

Electroforming

Electropolishing

Etching

Lacquering

Mass finishing

Mechanical plating

Polishing or buffing

Powder coating

Printed circuit boards

Solid film lubricants

Spray painting

PVD

None of the above

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Finishing Practices


17. Which types of inspection processes did your shop perform during the finishing process in2019? (Select ALL that apply)

Abrasion testing

Adhesion testing

Analytical chemistry

Atomic absorption analysis

Coating weight thickness testing

Continuity testing

Copper sulfate testing

Eddy current testing

Hardness testing

Humidity testing

Hydrogen embrittlement

Plating thickness

Porosity testing

Quench testing

Salt spray

Scanning electron microscope

Solderability testing

Solution analysis

Stress relief

Water immersion

X-ray thickness testing

XRF reading

None of the above

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18. Which types of inspection processes did your shop perform after the finishing process in 2019? (SelectALL that apply)

Abrasion testing

Adhesion testing

Analytical chemistry

Atomic absorption analysis

Coating weight thickness testing

Continuity testing

Copper sulfate testing

Eddy current testing

Hardness testing

Humidity testing

Hydrogen embrittlement

Plating thickness

Porosity testing

Quench testing

Salt spray

Scanning electron microscope

Solderability testing

Solution analysis

Stress relief

Water immersion

X-ray thickness testing

XRF reading

None of the above

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Finishing Practices


19. Which types of automation did your shop use in 2019? (Select ALL that apply)

Automated process lines

Process tank sensors

Track product quality and defects

Process monitoring

None of the above

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Finishing Practices


20. Which types of pretreatment did your shop use in 2019? (Select ALL that apply)

Solvent wipe

Blasting

Aqueous - zinc phosphate

Aqueous - iron phosphate

Aqueous - nano technology

Other

None

21. Which types of racking did your shop use in 2019? (Select ALL that apply)

Hook

Custom - built in-house

Custom - outsourced

22. Which stripping practices did your shop use in 2019? (Select ALL that apply)

Burn off – oven

Fluidized sand stripping

Chemical stripping

Water blast

Grinding

Other

23. Which curing methods did your shop use in 2019? (Select ALL that apply)

Infrared

Convection

Electric heat

Natural gas heat

Other

None

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Finishing Practices


Weekly or more Monthly Quarterly Every 6 months Once

Ovens

Guages

Inspection

24. About how often did your shop calibrate equipment in 2019? (Select ONE per row)

25. Did your shop have onsite an environmental room with temperature and humidity control in 2019?

Yes

No

Built in-house Purchased

Do not have this software

Preventative maintenance

Order management

Quality assurance

26. Please indicate how, if at all, your shop acquired software for the purposes listed below. (Select ONEper row)

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Business Strategy


This section of the survey includes questions pertaining to financial, operational and customerinformation.

Products Finishing is looking to take Top Shops analysis to the next level by determining the key drivers ofrevenue and profit margin. To do this, we will correlate all the data within the survey – both the numericaldata and answers to the yes/no and select-all questions – with revenue and profit margin. We can only runthese correlations and determine the key drivers of revenue and profit margin if you all answer all of theseimportant financial questions.

Note these measures are designed to allow comparisons across shops without having to disclose specificfinancials. Be assured that all responses are confidential to the staff of Products Finishing and will not beshared by any outside agency or organization.

Please read the instructions at each question for the accepted format for entering your data. If you receivean error message, please check for the correct format. It is also possible your response is consideredoutside the reasonable range for that question.

27. Please provide your shop's 2019 gross sales per finishing line in dollars. Example: If your gross sales were $5000 and you have 2 lines, you would enter 2500. Please round to thenearest whole number and enter without any signs or symbols.

28. Please provide your shop's 2019 gross sales per employee in dollars. Example: If your gross sales were $5000 and you have 20 employees, you would enter 250. Please roundto the nearest whole number and enter without any signs or symbols.

29. Were any capital investments made in equipment for your shop in 2019? (Select ONE only)

Yes

No

Not sure

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Business Strategy


If you receive an error message, please check for the correct format. It is also possible yourresponse is considered outside the reasonable range for that question.

30. Please provide your shop's 2019 capital equipment expenditure as a percentage of gross sales. Roundto the nearest whole number and enter without a % sign. Formula = (2019 cap equip exp / 2019 gross sales) * 100 Example: If your capital equipment expenditure were $500 and your gross sales were $5000, youwould enter 10. You may enter decimals but no other signs or symbols.

31. Please provide your shop's percent change in annual sales from 2018 to 2019 using the followingformula. Round to the nearest whole number, using a minus sign if necessary. Formula = [(2019 gross sales - 2018 gross sales) / 2018 gross sales] * 100Example: If your 2019 sales were $5000 and your 2018 sales were $4000, you would enter 25.

32. Please estimate your shop's percent change in annual sales from 2019 to 2020. Round to the nearestwhole number, using a minus sign if necessary. Formula = [(2020 estimated sales - 2019 gross sales) / 2019 gross sales] * 100Example: If your estimated 2020 sales are $4000 and your 2019 sales were $5000, you would enter -20.

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Business Strategy


33. Please provide your shop's 2019 net income relative to gross sales, rounded to the nearest wholenumber. Include a minus sign if your number is negative.Formula = [(2019 net income / 2019 gross sales)*100] Example: If your 2019 net income were negative $300 and your gross sales were $5000, you would enter -6.

34. Please provide your shop's 2019 net income relative to total assets, rounded to the nearest wholenumber. This is ROA on your shop's balance sheet. Include a minus sign if your number is negative.Formula = [(2019 net income / 2019 total assets) * 100] Example: If your 2019 net income was negative $300 and your total assets were $10,000, you would enter-3.

35. There is no single formula that fits how every shop figures capacity utilization. For this question, thinkabout what you consider to be at full capacity for your shop. Then enter as a percentage the degree towhich your shop’s total capacity was typically in use in 2019. Example: If 85% of your shop’s total capacity was typically in use in 2019, meaning you typically had 15%capacity to spare, you would enter 85 for capacity utilization.

36. Please provide your shop's 2019 overall profit margin percentage. Enter your number without a % sign. You may enter decimals but no other signs or symbols.

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Business Strategy


37. Please provide your shop's total revenue for 2019.Round to the nearest whole number and enter without any signs or symbols.

Plating

Anodizing

38. What percentage of your shop's 2019 total revenue came from each process?Please round each percentage to a whole number and enter without a % sign. Your percentages must sumto 100.

Functional

Decorative

39. What percentage of your shop's 2019 total revenue came from each type of finishing?Please round each percentage to a whole number and enter without a % sign. Your percentages must sumto 100.

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Business Strategy


40. Which of the following supply chain practices did your shop use in 2019? (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

41. Which of the following marketing tools did your business use in 2019? (Select ALL that apply)

Blogs

Brochures/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

YouTube

None of the above

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Business Strategy


Please provide the following measures for your business for 2019. Note these measures aredesigned to allow important comparisons across shops without having to disclose specificfinancials. If you receive an error message, please check for the correct format. It is also possibleyour response is considered outside the reasonable range for that question.

42. How many active customers did your business have in 2019?

43. What was your shop's customer retention rate for 2019? This is the number of your shop's customers in2019, who were also customers in 2018, as a percentage of your total 2018 customer base. Enter yournumber without a % sign.Example: If you had 50 customers in 2019 who were also customers in 2018, and a total of 60 customersin 2018, your customer retention rate would be 83%, and you would enter 83. You may enter decimals butno other signs or symbols. For numbers less than 1%, please round to 1.

44. What percentage of new business quoted in 2019 was actually booked? Enter your number without a %sign.Example: if you quoted 80 new jobs in 2019 and booked 40, you would enter 50. You may enter decimalsbut no other signs or symbols.

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Business Strategy


Plating

Anodizing

45. How much did your shop spend in dollars on materials for each of these processes in 2019?Please enter numbers only, rounding to the nearest whole number; decimals, symbols and words are notaccepted.

Automated or Manual Plating Line

Poly Tanks/Liners

Steel Tanks/Liners

Racking

Barrels/Baskets

Auxiliary equipment (pumps, ovens, power supplies, etc.)

Plating chemistries

Pretreatment processes

46. How much do you estimate your shop will spend, in dollars, to make purchases in thesecategories in 2020? Enter '0' if you expect to make no investment in a category in 2020. Please enter numbers only, rounding tothe nearest dollar; decimals, symbols and words are not accepted.

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Business Strategy


47. What coating or services would you like to add to your shop in 2020? (Select ALL that apply)

Anodizing Hardcoat

Anodizing Sulfuric

Black Chrome


Black Nickel

Black Oxide

Brass

Bronze

Bronze, White

Cadmium

Chromate

Chrome, Decorative

Chrome, Hard

Copper

Gold

Nickel, Chrome

Nickel, Decorative

Nickel, Electroless

Nickel, Industrial

Passivation

Phosphating

Pickling

Plating on Plastic

PVD

Rhodium

Silver

Tin

Tin-Lead

Tin-Nickel

Zinc

Zinc/Cobalt

Zinc/Iron

Zinc/Nickel

Zinc/Tin

None of the above

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Shop Profile


This section of the survey includes questions pertaining to the general characteristics that helpdefine your shop.

48. Which category best describes your shop's relation to its customer base? (Select ONE only)

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)

49. Which of the following best describes your shop's business? (Select ONE only)

High mix/low volume

High mix/high volume

Low mix/low volume

Low mix/high volume

50. Which statement best describes your shop's pricing strategy relative to competition? (Select ONE only)

Among the highest priced

Higher priced than average, but not among the highest

Priced about average

Lower priced than average, but not among the lowest

Among the lowest priced

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Shop Profile


You may need to refer to company data to answer the following questions. Please take the time todo so in the interest of data quality and to receive the report.

51. As of the end of 2019, about how many years will your shop have been in business? Please round to the nearest whole number.

52. About how many total parts did your shop finish in 2019? Please enter a whole number only; no commas or other symbols.

53. About how many different types of parts/SKU's did your shop finish in 2019? Please enter a whole number only; no commas or other symbols.

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Shop Profile


Plating

Anodizing

54. Switching gears a bit and now thinking about your shop’s finishing lines, how many lines were inproduction for each process in 2019? Please enter whole numbers only; no commas or other symbols.

Plating

Anodizing

55. How many lines of each type, if any, did your shop add in 2019?

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Shop Profile


56. Which of the following industries does your shop typically serve? (Select ALL that apply)

Aerospace

Agriculture/construction equipment

Appliances

Automotive

Architectural 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 specify)

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Shop Profile


57. Which of the industries served do you typically consider THE PRIMARY contributors to your shop'sbusiness? (Select up to 5)

Aerospace

Agriculture/construction equipment

Appliances

Automotive

Architectural 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

[Insert text from Other]

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Shop Profile


58. Which certifications, if any, does your finishing shop have currently? (Select ALL that apply)

ISO 9001

ISO 13485

ISO 16949

AS9100

NADCAP

None of the above


59. Of which trade associations was your shop a member in 2019? (Select ALL that apply)

Aluminum Anodizers Council (AAC)

National Association for Surface Finishers (NASF)

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Shop Profile


60. Which approvals did your finishing shop hold in 2019? (Select ALL that apply)

Aerojet

BAE Systems

Bell

BMW

Boeing

Caterpillar

Cessna Aircraft

Chrysler

Eaton Aerospace

Ford

GE

General Dynamics

GM

Goddard Space Flight (NASA)

Honda

Honeywell

IBM

John Deere

Lockheed Martin

Lycoming/Textron

Martin Marietta

MD Helicopters

Mercury Marine

MOOG

Motorola

Nissan

Northrop Grumman

Raytheon

Rolls Royce Corp.

Sikorsky Aircraft

Toyota

United Technologies

None of the above


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Training and Human Resources


This section of the survey pertains to employees, training, and shop safety.

61. How many total people did your shop employ in 2019 at the location(s) your answers pertain to?

62. How many employees at this location were shop floor employees in 2019?

63. How many employees at this location were Certified Electroplater Finishers (CEF) in 2019?

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64. Thinking of the total number of employees at this location, do you plan to increase, decrease, or keepthe same number of employees in 2020? (Select ONE only)

Increase

Decrease

Keep the same

65. What was your shop's annual labor turnover rate for all shop floor employees in 2019? This is thenumber of voluntary plus involuntary separations of shop floor employees as a percentage of the usualtotal number of shop floor employees. Enter your number between 0 and 100 without a % sign.You may enter decimals but no other signs or symbols. Example: If 6 shop floor employees left in 2019 and your usual shop floor staff totals 30, you would enter20.

66. Did your shop have any accident incidents in 2019? (Select ONE only)

Yes

No

Not Sure

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67. What was your shop's annual accident incident rate for shop floor employees in 2019? This is thenumber of shop floor accident incidents as a percentage of the typical number of shop floor staff. Enteryour number without a % sign.Example: if you had 2 accident incidents in 2019 and your shop floor staff typically totals 30, you wouldenter 6.67. You may enter decimals but no % sign.

68. Which of the following designated safety roles did your shop have in place in 2019?

Safety manager

Safety committee

None of these

69. What was your shop's insurance Experience Modification Rate (EMR) for 2019?

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70. What was the average hourly wage rate for hourly paid, non-management shop floor personnel in2019 excluding overtime? Please enter a number. You may enter decimals but no other signs or symbols.

71. Which human resource practices/programs did your business use in 2019? (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

72. Were any of your shop's employees part of a union in 2019?

Yes

No

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This is the final page of the survey. Please double-check your responses for accuracy and completenessbefore you continue.

Once you click Submit Responses on this page, you will be taken to the Products Finishing website. Yoursurvey will be locked and submitted and you will not be able to change any of your answers. Before youclick Submit Responses, you may close and return to the survey on this device to make changes asmany times as you like until the deadline on January 10, 2020.

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welcome to top shops plating & anodizing products ... · products finishing top shops 2020:...

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