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As part of our ongoing commitment to helping organizations achieve high performance, Accenture regularly conducts substantive research to shed light on key challenges our clients are facing and provide thoughtful guidance clients can consider in addressing those challenges. An important part of Accentures broader research efforts is our study of manufacturing. When we conducted the previous edition of our manufacturing study in 2011, we wanted to understand how manufacturers in United States had fared in the two years since the official end of the recession in June 2009 and where they saw their business and most important markets headed in the near future. We also wanted to get a sense of how companies were preparing for the future as they tried to reconcile their manufacturing operations to accommodate intensified, multifaceted volatility. What we found was manufacturers had seen an uptick in revenue during that time and were working to prepare their operations once again for growth. In 2013, we expanded the scope of our research to a global base of manufacturers in North America, South America, Asia and Europe that had global operations. Our goals for this most recent effort were largely the same as beforeto understand
how companies were performing and how they were aligning their operations with market challenges and opportunities. As youll read on the following pages, our research uncovered some very intriguing findings. From those findings, we gleaned four high-level insights. One, more than ever manufacturers need to align their investments to foster greater operational flexibility. Volatility is the new normal, and companies that are unable to quickly shift gears when the market changes are on the fast track to obsolescence. Two, globally consistent, repeatable operating models and reliable, predictable production facilities are fundamental to enabling the flexibility required in todays market. Three, digital technologies are becoming increasingly important in manufacturers efforts to improve their performance across the enterprise by streamlining processes, enabling faster and better decisions, and creating stronger relationships with customers. And four, manufacturers must excel on multiple fronts to be successful. The ability to balance critical factors such as cost, risk, flexibility, quality is critically important to competitiveness and growth.
One group of companies in this years research stood out in this regard. This cadre of manufacturing leaders are growing much more strongly and profitably than others in large part because they recognize the importance of operational flexibility to high performance and are committed to investing in the capabilities that will foster it. We believe there is much that other manufacturers can learn from how these leaders approach their business, as well as from our research findings overall. On behalf of Accenture, Id like to thank those manufacturing executives who gave their valuable time to participate in our study. I hope you find the results informative and useful as you consider how best to organize and equip your operations to execute your growth strategies in the coming year and beyond.
Russell Rasmus
Managing Director for Manufacturing Accenture
CoNtENtS
IntroduCtion KeY ResearCH FindinGs Perspectives on Growth Capturing Growth Driving Consistency and Flexibility Through Production Systems Avoiding the Pitfalls of Facility Relocation or Startup Getting the Most From Contract Manufacturing Solving the Manufacturers Skills Dilemma A Formal, Collaborative Approach to Asset Reliability Manufacturing Leaders The Benefits of Becoming a Digital Business How a Control Tower Can Help Manufacturers Make Better Production Network Decisions The Sustainability Journey: From Compliance Assurance to Performance Assurance AppendiX Methodology and Demographics 3 7 7 9 11
15 18 22 25
28 29 33
39
ConClusion 41 42 42
INtroDuctioN
The headlines in the media today offer a glimpse of the challenges manufacturers confront on a daily basis:
So which is it? Is the global economy a future train wreck, as one publication described it, heading for a fresh round of slowdowns, layoffs and cash crunchesor worse? Or has it turned the corner and are better days ahead? Unfortunately for manufacturers, its both. The fact is, todays economy remains as volatile and unpredictable as ever, with pockets of strong growth counterbalanced by sluggish demand and positive trends neutralized by negative ones. Thats causing headaches for all companies, but especially manufacturers, which face the formidable challenge of ensuring its asset-intensive, highly complex operations are capable of continually switching gears to accommodate the global economys ongoing stops and starts. To shed light on the factors shaping manufacturing in todays environment, as well as how manufacturers are refining their manufacturing strategy and operations to remain successful, Accenture embarked on a comprehensive research study of major manufacturers around the world. The study included a survey of 250 senior manufacturing executives in large companies headquartered in North America, Europe, South America and Asia. These companies have global operations and represent six main industry sectors (automotive, consumer products, industrial equipment, electronics and high tech, oil and gas, and chemicals and natural resources). At a high level, our survey revealed that while manufacturers overall are growing and remain optimistic about their prospects in the near future, economic and market volatility and shortcomings in critical areas of their operations could pose a threat to their growth agenda. More specifically, the following key findings emerged from our research:
Patchy world economy weighs on quarterly profits yet Upbeat forecasts adds to optimism over economic recovery. Asian economies encounter stiff winds but Consumer confidence high in southeast Asia. Europe continues to weaken world economies although European shares jump amid economic optimism. IMF issues dreary report card on future of world economy however Businesses pick up hiring on increased economic optimism. Asian stocks advance on China growth yet Global economy shifts as China falters, Japan, U.S. Rebound.
Penetration into emerging economies will shift the source of manufacturers revenues.
The market in which a manufacturer is based is likely to be among the companys three largest markets in terms of current revenue. Today, the United States, followed by China, are among the top three markets for the largest percentage of manufacturerswhich is not surprising given those are the worlds biggest markets. However, executives anticipate that within a few years, China and Brazil will become much more important sources of revenue.
Introduction
Introduction
Economic and market volatility is the overriding threat to manufacturers growth agenda.
While manufacturers performance in the past few years has been encouraging and optimism runs highpossible storm clouds remain on the horizon. Executives participating in our study cited a variety of volatility-related factors as potential impediments to their ability to grow including global currency instability, unpredictable commodities costs, uncertainty about customer demand, political or social unrest in key markets, and potential changes in government regulations.
manufacturing leaders, were far more likely than other companies in our study to also report having grown revenue by more than 10 percent since 2011 and to anticipate growth of more than 10 percent in 2013. Helping to drive such compelling business results are some underlying approaches and practices that leaders employand that are less evident among the rest of our survey sample. For example, leaders possess a strong belief that the ability to flexibly and dynamically alter production to match demand is critical to achieving their growth goalsand consequently have built an operating model that effectively accommodates the dynamic shifting of resources and activities both to different physical locations in their manufacturing network and within a specific facility in response to market developments or changes in demand. To support flexibility, leaders continually make adjustments to their production facility network to help them meet demand and control operating costs. For instance, leaders are twice as likely than other manufacturers to have relocated manufacturing operations since 2011, to have started new operations during that time, and to be considering relocating manufacturing operations in 2013 and 2014. Leaders also are much more likely to be planning to increase the use of contract manufacturing and see contract manufacturing in a more strategic light. While non-leaders view contract manufacturing as merely a way to relieve short-term capacity constraints, leaders see it as part of their long-term strategy and an important component of their broader production facility network. Leaders also appear to be more advanced than others in key capabilities that are critical to operating more flexibly and dynamically. They are likely to have a good understanding of the local cultural differences and needs in its most important revenue markets; be highly adept at accurately sensing market changes or opportunities before competitors do; have full visibility into its networks operations that enables them to effectively manage the network and make appropriate decisions to balance demand and capacity; and extensively use modular and consistent business processes and policies that enable them to quickly and dynamically allocate
Digitization of manufacturing is creating challenges in attracting and retaining the right talent.
Overall, manufacturers in our survey appear to be confident they have a talent strategy that enables them to hire, develop and retain the skills they need to compete effectively, and more than three-quarters have increased their manufacturing workforce in the past few years. Yet many manufacturers still have several skills gaps primarily because they are unable to find or unwilling to pay the going rate for the more advanced skills needed in the digital environment.
Manufacturers are striving to strike a balance between investments in new and existing assets.
Participating companies continue to make capital investments in new plants and manufacturing equipment and technologies, as well as investments in initiatives to increase the efficiency and productivity of individual manufacturing facilities, and in information technology solutions. However, a large majority of manufacturers also said they are focused on extending the life and contributions of existing assets through initiatives such as applying lean principles to reduce waste, total productive maintenance, automation technology, and analytics. In addition to the preceding, our research also enabled us to identify some of the advanced practices that correlate strongly with superior business performance. A small group of companies in our surveyabout 8 percentreported having increased their production levels, profitability and labor efficiency by more than 10 percent since 2011. This group, which we deemed
Introduction
manufacturing capacity across the facility network (including contract manufacturers) in response to changes in its markets. When it comes to people, leaders have a talent strategy that enables them to acquire or build the skills they need to compete effectively, are voracious acquirers of talent, focus their hiring on people in countries where demand is strongest or who have skills that are strategically important to the company, and tend to build a diverse workforce that includes full- and part-time employees, contractors and consultants. Finally, leaders increasingly are looking to make their current operations more reliable and responsive, which in turn boosts labor efficiency and supports a more flexible and dynamic facility network that can enable them to more easily adapt to changing market conditions. For instance, leaders are twice as likely as others to be focused on extending the life and contribution of
existing assetsparticularly through total productive maintenance and the use of operations analytics to help improve the efficiency and productivity of individual manufacturing facilities. Theres no doubt that these remain challenging times for manufacturers, even those that are optimistic about growth. But as the manufacturing leaders in our study suggest, those that are able to infuse a high degree of flexibility in their operations, squeeze more capacity and productivity out of the assets and infrastructure they already have, and get the right people in place where they are most needed are best positioned to grow and thrive in todays volatile global economy.
Introduction
Perspectives on Growth
While some countries economies continue to experience the lingering effects of the Great Recession, manufacturers overall have rebounded. An overwhelming majority of manufacturers in our survey have experienced strengthening business performance in the past few years and most anticipate that trend to continue in the near future. Ninety-three percent of executives surveyed said their companies have posted overall revenue growth since 2011 (Figure 1) and virtually all manufacturers anticipate some growth in 2013 (with 63 percent anticipating at least six percent). For 60 percent of manufacturers, growth is expected to be mostly or entirely organic, compared with 21 percent, which believe growth will be primarily or entirely through inorganic means such as M&A, joint ventures, and alliances. Manufacturers output has increased as well, with 94 percent reporting their companys total production level has increased (Figure 1). Driving that output has been an increase in capacity: More than two-thirds of manufacturers overall said they increased capacity since 2011, with nearly three in 10 indicating the increase was more than 20 percent. Perhaps most important is that margins are up. Ninety percent of manufacturers have increased their overall profitability since 2011, and 22 percent have boosted profits by more than 10 percent (Figure 1). What is the source of manufacturers growth? The United States was cited by the largest percentage of manufacturing executives as the country from which their company currently derives most of its revenue, followed by China.
Furthermore, confidence in these markets remains strong. Regardless of which specific markets executives cited as their top three, 44 percent said they are highly optimistic these economies will grow in the next 12 months. Forty-one percent indicated moderate optimism, while just 15 percent said they were pessimistic about growth in their top markets. Beyond next year, executives see changes afoot as emerging markets appeared poised to make gains at the top of the list, with China and Brazil expected to grow in importance. However, while manufacturers remain optimistic about their business and their markets, the current environment is not without its challenges. One of the biggest challenges manufacturers face is the economic and market volatility that prevails in many markets and remains a major concern among manufacturing executives in all regions, especially those in mature markets. Executives participating in our study cited a variety of volatility-related factors as potential threats to their growth agenda, including global currency instability, unpredictable commodities costs, uncertainty about customer demand, political or social unrest in key markets, and potential changes in government regulations (Figure 2). Given these challenges, it is not surprising that 82 percent of executives overall agreed or strongly agreed that the ability to flexibly and dynamically move production from one existing facility to another, or to change the product mix at an existing facility to match demand, is critical to achieving their growth goals.
Perspectives on Growth
Figure 1: Total revenue growth, production level and profitability since 2011.
40% 35% 30% 25% 24% 20% 15% 10% 5% 4% 0% 2% 3% 4% 4% 7% 20% 22% 36% 36% 35% 36% 31%
34%
Flat
Total Production
Figure 2: Issues manufacturers indicated could impact their ability to grow in 2013-14.
Global currency instability Unpredictable commodities cost Stronger competitors Pressure to reduce operational costs Uncertainty about customer demand Political/social unrest in key markets Potential changes in federal government regulations Applying innovation to stay ahead of the competition Weaker pricing power for finished goods/services Aging workforce/shortage of talent Extreme weather/natural disasters Shortage of commodities 15% 15% 14% 22% 25% 24% 27% 29% 33% 32% 36% 43%
Perspectives on Growth
Capturing Growth
As they pursue growth, manufacturers will rely on a number of levers to maintain or improve profitability. The most popular lever by far is improving operational efficiency, followed by improving quality, reducing labor costs, reducing inventory levels, and reducing material costs (Figure 3). Manufacturers also recognize that robust, sustainable growth is dependent on a solid base of operationsa base that includes the right production facility network, talent, and operating model that can help support the operational flexibility executives see as critical to driving growth. According to executives participating in our survey, manufacturers have made solid progress in these areas, but shortcomings in key aspects of their operations remain that could make it difficult for them to achieve their growth goals.
in demand. However, in no case was a specific dimension described by more than 27 percent of respondents as providing very effective support (Figure 4). The scenario is slightly better when it comes to supporting flexibility inside a single location. Nearly two-thirds said various aspects of their operating model accommodate to some degree the dynamic shifting of resources and activities within a specific facility (for example, switching over to producing a different product mix) in response to market developments or changes in demand. But again, no dimension was named by more 28 percent as providing very effective support (Figure 5). More specifically, executives feedback indicated shortcomings in key capabilities that can be critical to operating more flexibly and dynamically. For instance: Only 24 percent of executives strongly agreed their company is highly adept at accurately sensing market changes or opportunities before competitors do. Just 26 percent strongly agreed their company extensively employs modular and consistent business processes and policies that enable it to quickly and dynamically allocate product design and manufacturing capacity across the facility network (including contract manufacturers) in response to changes in its markets. Only 29 percent of executives strongly agreed that their company has full visibility into its networks operations, enabling them to effectively manage the network and make appropriate decisions to balance demand and capacity. Forty percent strongly agreed their company has a good understanding of the local cultural differences and needs in its most important revenue markets.
Operating model: More work needed to support flexible and dynamic shifting of resources to accommodate changes in demand
Recognizing the highly volatile business environment in which they operate, manufacturers are adapting key aspects of their operating model to make their operations (both network-wide and at the specific facility level) more flexible and dynamic and, thus, help improve overall operational and financial performance. However, most manufacturers have experienced uneven progress in creating more flexible and dynamic operations and consider improving their capabilities in this regard to be an important priority in the short term. Nearly 60 percent of all manufacturers indicated various aspects of their operating model accommodate to some degree the dynamic shifting of resources and activities to different physical locations in their manufacturing network in response to market developments or changes
Capturing Growth
Figure 3: Most common levers manufacturers will use to maintain or improve profitability.
Improving operational efficiency Improving quality Reducing labor costs Reducing inventory levels Reducing material cost Improving throughput in current facility 12% 35% 33% 31% 30% 57%
Figure 4: How effectively manufacturers operating model accommodates flexibly and dynamic shifting of production across different physical locations.
Organization structure and incentives system Information technology infrastructure Production facility network Business processes, policies, and capabilities Information technology applications Talent/skills base 3% 3% 4% 5% 3% 3% 6% 11% 9% 12% 12% 10% 1 - Very ineffectively Note: Due to rounding, totals may not equal 100% 30% 26% 29% 28% 29% 32% 2 3 33% 39% 41% 30% 32% 35% 4 27% 20% 17% 26% 23% 20% 5 - Very effectively
Figure 5: How effectively manufacturers operating model accommodates flexibly and dynamic shifting of production within a single location.
Organization structure and incentives system Business processes, policies, and capabilities Information technology infrastructure Talent/skills base Production facility network Information technology applications 4% 3% 4% 2% 3% 6% 6% 8% 10% 11% 9% 8% 1 - Very ineffectively Note: Due to rounding, totals may not equal 100% 25% 24% 26% 27% 29% 27% 2 3 37% 38% 35% 39% 40% 34% 4 28% 26% 25% 21% 19% 24% 5 - Very effectively
Capturing Growth 10
11 Capturing Growth
Capturing Growth 12
The good news is that executives recognize their companies could do better and plan to take action. Seven in 10 said improving their companys operating model is a priority in the next 12 months (Figure 6). More than half said their companies are planning to invest in strengthening their talent and skills base in the next 12 months and nearly half indicated they are doing the same for their business processes, policies and capabilities. And about one-third said they anticipate investing in their organization structure and incentive systems, as well as in their IT infrastructure and IT applications (which are critical to manufacturers efforts to become a more digital business (Figure 7). Figure 6: Percentage of manufacturers believing it is a priority to improve their operating model.
Very significant 29% Significant
As they make such investments, manufacturers should be mindful of the important role that consistency can play in fostering flexibility in their operating model. Without a high degree of global consistency and standardization across their business processes, policies, skills and other capabilities, manufacturers may find it difficult to easily move production within or across facilities when market developments demand it.
was located in the United States (26 percent), followed by Germany (19 percent). Conversely, the biggest beneficiaries of manufacturers moves were China (34 percent) and Brazil (23 percent), although the United States also was a popular landing spot for relocated facilities for 13 percent of respondents. The relocation trend looks to continue in the next 12 months, with 37 percent of executives surveyed also saying their companies are considering relocating operations during that timemostly to reduce labor costs and enter a new market. Reducing transportation costs appears to be less of a driving factor for future relocations than they were with previous initiatives In addition to moving existing facilities, nearly half of the manufacturers in our study said they started new production facilities since 2011with the overwhelming favorite site being China (45 percent), followed by Brazil (30 percent), the United States (25 percent), and Africa (16 percent). Again, the most prevalent reasons for starting a new facility were entering a new marketwhich, perhaps, helps explain the increased popularity of Africa in this years studyreducing labor costs, and reducing transportation costs (Figure 9).
Production facility network: Plants are being relocated or built to support new market entry and reduce costs
As the pattern of demand continues to change, manufacturers face the ongoing need to evaluate where and how they make their products to improve responsiveness to customers while reducing overall operational costs. Such assessments can often result in the decision to relocate production facilities from one country to another or start up a new facility in a new market. Since 2011, about four in 10 manufacturers surveyed reported having relocated production facilities to new locations primarily to enter a new market, reduce transportation costs, or reduce labor costs (Figure 8). The relocation of facilities, at a global level, is indicative of a greater focus by manufacturers on emerging, growing markets. For instance, of those relocating operations, the largest percentage said the facility they shut down to make the move
44%
Figure 7: Aspects of the operating model in which manufacturers plan to invest in 2013-14.
Talent/skills base Business processes, policies, and capabilities Information technology infrastructure Information technology applications Organization structure and incentives system Production facility network None 4% 23% 34% 34% 38% 47% 56%
13 Capturing Growth
Entering a new market Reducing labor costs Reducing transportation costs 49% Increasing responsiveness / reducing lead time to customers Taking advantage of needed skills in that location Capitalizing on government incentives Desiring to improve quality Capitalizing on currency or tax advantages Minimizing intellectual property theft 49% Gaining access to needed workforce skills Desiring more favorable government regulations Yes No 2% 2013 Global Not sure Developing a new product that needed specialized operations Reducing the impact of volatile or rising oil prices 17% 17% 16% 16% 14% 12% 11% 9% 26% 25% 23% 30%
33%
Capturing Growth 14
15 Capturing Growth
26% 54%
50%
46%
It will help us relieve short-term capacity constraints Use of contract manufacturing is part of our long-term strategy
2013 Global
Figure 11: Capabilities manufacturers could strengthen to improve facility location decisions.
Total cost analysis of options Skills and knowledge of staff Improved understanding of local market capabilities A comprehensive manufacturing location strategy Changing internal mindset to a longer-term, total value view 21% 40% 48% 46% 55%
As part of their production network, manufacturers also are planning to increase their use of contract manufacturing. Threefourths of those in our study said they will increase moderately or extensively their use of contract manufacturing in the next 12 months, with 54 percent doing so to relieve short-term capacity constraints and 46 percent considering contract manufacturing a part of their long-term strategy (Figure 10). Of course, determining where to locate production facilities can be a complex endeavor, especially when opening plants in new markets. Executives in our survey indicated they could make more effective location decisions by improving several key capabilities within their organizationsespecially their ability to conduct total cost analyses of the location options when considering where to move or startup a facilitywhich is
significant given that cost is the primary driver of location decisions among a large majority of manufacturers (Figure 11).
enables them to hire, develop and retain the skills they need to compete effectively in a todays economic environment. Manufacturers also have been active in bringing new people aboard. Since 2011, more than three-quarters of companies surveyed have increased their manufacturing workforce (Figure 12). Of those, manufacturers were most commonly adding skills that are strategically important and in countries where demand was strongest. Workers hired were more likely to be fullor part-time salaried workers as opposed to hourly workers or contractors. Among the small minority of manufacturers that actually decreased their workforce since 2011, reductions tended to be centered in countries where demand was weakest, and those eliminated were most likely to be full- or part-time contractors.
Talent: Manufacturers continue to hire and improve labor efficiency, but many face major talent gaps in key workforces
Its a given that people are the key to a companys success. Companies that excel in getting the right talent on board and developing critical skills in the workforce typically are better positioned for sustained high performance over time. Overall, manufacturers in our survey appear to be confident they have what it takes to build the right workforce for their business. Eighty-three percent of executives surveyed agreed their companys talent strategy
Capturing Growth 16
17 Capturing Growth
Capturing Growth 18
Please indicate how each of the following describes your approach to increasing your manufacturing workforce. We added workers whose skills were determined to be strategically important to the company Our increases tended to be centered in countries where demand was strongest We tended to eliminate workers in the lowest tier of performance Workers added were more likely to be full- or part-time salaried employees Workers added were more likely to be full- or part-time hourly employees Workers added were more likely to be temporary or full-time contractors 6% 5% 5% 7% 8% 8% Strongly disagree Note: Due to rounding, totals may not equal 100% 9% 11% 16% 13% 15% 17% Somewhat disagree 21% 16% 29% 23% 34% 29% Neither agree nor disagree 34% 38% 29% 38% 27% 32% Somewhat agree 30% 29% 21% 19% 16% 15% Strongly agree
Figure 13: Plans for change in use of various types of workers in 2013-14.
51% 39% 33% 29%
47%
24%
Consultants
19 Capturing Growth
This hiring trend appears poised to continue in the near future, with two-thirds of executives saying their companies plan to increase their overall manufacturing workforce by at least 5 percent between 2013 and 2014. The increase will largely be driven by boosts in the number of predominantly full-time employees and, to a lesser extent, contractors (Figure 13). Despite their vigorous hiring, however, many manufacturers still have several skills gaps, mostly in the blue-collar workforce (Figure 14) where they struggle to attract
the needed skills because they cannot pay what the talent demands. Nearly four in 10 respondents said their company has a sizable skills gap in their skilled trades labor workforce, and 35 percent said the same about their general labor workforce. The smallest gaps across all companies were seen at the top of the management hierarchy supervisors and executives. Regardless of where the gaps are, most manufacturers rely on a few key levers to close them and improve overall workforce performance (Figure15): performance
rewards tied to both individual success and enterprise profitability, competitive salaries and benefits, encouragement from leadership to pursue innovation and share ideas, training to keep the workforce current, and formal competency models that define required skills, career levels and appropriate curriculum.
Figure 15: Levers manufacturers use to close skills gaps and improve workforce performance.
Performance rewards tie to both individual success and enterprise profitability Competitive salaries and benefits are offered Leadership encourages innovation and provides employees with opportunities to share ideas Training is used to keep the workforce current and re-training is used rather than hiring/firing Formal competency models are in place defining required skills, career levels and appropriate curriculum Individuals are encouraged to proactively seek training on new topics and technologies Career advancement includes rotations through various roles and assignments to different countries or facilities Well-defined talent sourcing and selection strategy is in place Employee satisfaction surveys are conducted regularly and results are shared Global and local communities of practices, effective at sharing knowledge Full participation in coaching and mentoring activities Real-time critical feedback is provided and is an embedded part of the company's culture 12% 19% 22% 29% 28% 28% 32% 37% 40% 39% 46% 45%
Capturing Growth 20
21 Capturing Growth
Although manufacturers in our study continue to hire workers and are confident in their talent strategy, many face major talent gaps in key workforces that could constrain their growth and make it difficult for them to keep pace with market demands. For instance, since 2011, more than threequarters of companies surveyed have increased their manufacturing workforce, focusing primarily on bringing in full- or part-time salaried workers with skills that are strategically important and in countries where demand was strongest. A large majority of executives surveyed agreed their companys talent strategy enables them to hire, develop and retain the skills they need to compete effectively in a todays economic environment. Yet many manufacturers remain plagued by skills gaps, especially in the trades labor and general labor workforces. Perhaps one reason is that just 28 percent of manufacturers said they had a well-defined talent sourcing and selection strategy in place. Given these gaps, and the need to continue building a robust workforce to achieve their growth goals, what steps should manufacturers take to attract, retain and build the skills they need? In our experience, the following have proven very effective.
understand what it should look for in new recruits. Formal competency models also can help manufacturers define required skills and career levels (something that only 37 percent of manufacturers in our survey have in place).
together on common initiatives. In such an environment, new types of rewards and incentives are important to encourage the desired behaviors outcomes.
Work with institutions further back in the talent supply chain to build the needed skills.
Manufacturers in many industries are finding it increasingly difficult to find qualified talent, especially people with the technical skills that are still critically important to a manufacturers business. To help fill that void, manufacturers should consider how they can partner with high schools, trade schools and community colleges to build curricula that can expose students to the skills manufacturers need. That way, when students do come on board, they have a head start on the skills that companies can mold and develop further.
As they continue to look for ways to fill their skills gaps, manufacturers should keep in mind a simple rule of thumb
In a typical organization, one-third of employees are high performers, one-third are acceptable performers, and one-third perform below standards and generally are unable or unwilling to make the transition to one of the other groups. How effectively a company addresses these three different segments has a major impact on an organizations overall skills base and, ultimately, on the success of the broader enterprise.
Capturing Growth 22
While these initiatives may have fallen short in helping manufacturers close their skills gaps, they appear to have contributed to an increase in overall workforce efficiency. Since 2011, about one-half of manufacturers said their labor efficiency has increased between 1 percent and 5 percent, onefourth said it rose between 6 percent and 10 percent, and one-tenth said it improved by more than 10 percent (Figure 16). Such gains can help manufacturers increase existing assets capacity and are a key driver of broader operational efficiency across a manufacturers facility network. Figure 16: Change in manufacturers labor efficiency since 2011.
11% Increased by more than 10% Increased by 6% to 10% Increased by 1% to 5% Was unchanged 49% Decreased by 1% to 10% Decreased by more than 10% 13% 3% 2013 Global Note: Due to rounding, totals may not equal 100% Don't track / don't measure
Investments: Manufacturers are striving to strike a balance between investments in new and existing assets.
To help support their efforts to improve their operating model, optimize their facility network and enhance their workforce, manufacturers are continuing to make targeted investments in key areas of their business. These include capital investments in new plants and manufacturing equipment and technologies, as well as investments in information technology and efficiency initiatives. But many executives also said spending on new equipment and technology will be tempered by efforts to get more out of what they already have. Since 2011, three-quarters of manufacturers have made manufacturing capital investmentsmostly in manufacturing equipment and machines and in existing manufacturing plant infrastructure (Figure 17), and in the next 12 months, capital investment is expected to continue (Figure 18). However, 66 percent of manufacturers also said they will be focused on extending the life and contributions of existing assets. In other words, manufacturers are redoubling their efforts to clean up their shop and become more efficient. In doing so, they are looking to life-extending initiatives such as applying lean principles to reduce waste, total productive maintenance, automation technology, and analytics (Figure 19).
Finally, information technology also is on the investment horizon for a large majority of manufacturers, as these companies continue their quest to digitalize a wider range of their businesses: Nearly eight in 10 said they are planning initiatives in the next 12 months to strengthen their IT applications. The largest percentage indicated those initiatives would focus on performance management tools such as dashboards and metrics, followed by quality assurance, ERP solutions, manufacturing planning and scheduling, manufacturing execution systems, plant operations analytics, and enterprise asset management solutions (Figure 20). Of course, as they increase their investments in key areas of their business, manufacturers must feel confident that they have a disciplined approach in place in order to get the return on those investments. By formally measuring and monitoring the value those investments deliver, manufacturers will be in a better position to justify future investments that can substantially improve operational and financial performance.
23%
Manufacturing equipment / machine 75% Yes No 22% 2013 Global Note: Due to rounding, totals may not equal 100% 4% Not sure Manufacturing technology New manufacturing plant construction 49% 45% Existing manufacturing plant infrastructure
60% 59%
23 Capturing Growth
Figure 19: Initiatives manufacturers are pursuing to extend the life and contributions of existing assets.
Applying lean principles to reduce waste Applying total productive maintenance (TPM) Applying automation technology Applying analytics 21% 49% 48% 67%
Figure 20: Manufacturers information technology investment plans for the next 12 months.
Are you planning any initiatives in the next 12 months to invest in/strengthen your information technology applications? What type of initiatives are you planning?
Performance Management (Dashboard & Metrics) Quality Assurance (QA) ERP Solutions Manufacturing Planning and Scheduling (MPS) 77% Manufacturing Execution Systems (MES) Plant Operations Analytics Enterprise Asset Management (EAM) Computerized Maintenance Management Systems (CMMS) Training and Collaboration Software 23% Yes No 2013 Global Lab Information Management Systems (LIMS) Other 1% 30% 29% 26% 23% 21% 16% 16% 39% 38%
53%
Capturing Growth 24
Reliability and maintenancethe processes, tools and investments that help complex and expensive assets continue to run at peak operating performancehas always been important for manufacturers that operate in asset-intensive environments. Today, its even more vital for manufacturers, for a number of reasons. For starters, assets have become very sophisticated and complex which, while boosting functionality, also means there is much more to go wrong. Second, because of recent economic conditions, many companies have been unable or unwilling to invest in new assets and, instead, have been squeezing even more out of older assets that are more prone to problems due to the accumulation of wear and tear. And third, with sustainability assuming greater importance among manufacturers, the ability to make assets run more efficiently and reliably so they consume less energy is increasingly attractive. The importance of reliability and maintenance is evident in our survey: Two-thirds of manufacturers said they are focusing on extending the life and contributions of existing assets, with about half of those companies indicating they plan to deploy comprehensive preventive maintenance programs in support of that pursuit. As they seek to improve their assets performance and longevity, manufacturers can learn from some of the worlds most successful manufacturers, which have adopted leading reliability and maintenance practices that help enable them to avoid the inefficiencies, costly breakdowns and delays that can negatively impact balance sheets, reputations and customer relationships. These successful companies tend to have a highly structured understanding of their critical assets and whats needed to optimize those assets performance. For instance, the typical large production facility has tens of
thousands of production and automation assets, each of which requires different skills, tools, techniques and supplies to keep them running. Companies that excel in optimizing these assets are highly adept at knowing what each asset needs and determining which assets are the most critical to the companys performance (and, thus, deserve the most attention). Successful manufacturers also consider reliability a shared responsibility between production and maintenance. In some manufacturers, the production team sees keeping assets running as strictly the purview of the maintenance function. This can lead to a dangerous situation, in which the production team, seeking to maximize uptime and drive down cost per unit, neglects preventive maintenance schedules and essentially runs the asset until it failsat which time they call in the maintenance staff to repair it. But the time and cost associated with bringing an asset back online when it reaches this point can be far greater than what the company would have incurred had it simply followed its preventive maintenance routines. The companies with the most productive, efficient and reliable assets typically eschew this We run, you fix mentality in favor of a more collaborative approach that results in a more globally reliable network. These organizations understand that maximizing asset uptime is everybodys job, not just the maintenance functions. Furthermore, successful manufacturers are analytically driven. They understand that a key to keeping assets running is to understand the conditions that cause them to fail and avoid them. Thats where analyticsparticularly, predictive analytics can be extremely valuable. Using predictive analytics, successful manufacturers can create models that highlight the likelihood of
various events and the impact those events could have on an assets performance. Using such insights, the companies can take the appropriate steps to prevent the events from happening and, thus, minimize issues that could negatively affect asset performance. Finally, successful manufacturers dont shortcut maintenance during times of austerity. The maintenance line item in a manufacturing budget is an easy target when a company is faced with cost-cutting pressures. But saving a little in preventive maintenance can have a negative effect on product cost and quality and ultimately can end up costing a company significantly more when the asset fails. No matter their cost or quality, assets will likely fail to produce what is expected of them if they are not maintained properly. By developing and using a formal capability to proactively and collaboratively manage asset maintenance and reliability, manufacturers can optimize their assets contribution to the companys overall business performance.
25 Capturing Growth
Capturing Growth 26
27 Manufacturing Leaders
Manufacturing Leaders
While most manufacturers in our study have made varying degrees of progress in strengthening their operating model, plant location network, and core talent and technology capabilities, a small group of manufacturers have excelled in building truly flexible and dynamic operations. And as a result, these companies are better positioned to manage through volatility and uncertainty and mitigate operational risk; they have grown more strongly in the past few years; and they are better positioned to capitalize on growth opportunities in the future. As mentioned earlier, 90 percent or more of companies overall indicated their production levels and profitability have increased since 2011, and 83 percent said their labor efficiency rose during that period. However, a small group of companies, about 8 percent of those participating in our study, reported the highest level of performancean increase of more than 10 percent on all three metrics. We call this elite group of companies manufacturing leaders. Manufacturing leaders, which spanned the spectrum of organization size, were far more likely than other companies in our study to report having grown revenue by more than 10 percent since 2011 (90 percent versus 13 percent), to be highly optimistic
that the economies of their top revenue markets will grow in the next year (80 percent versus 41 percent), and to anticipate revenue growth of more than 10 percent in 2013 (95 percent versus 15 percent). Furthermore, leaders were much more likely to indicate they plan to grow entirely through organic means in 2013 (70 percent versus 17 percent), as well as to strongly agree that the ability to flexibly and dynamically alter production to match demand is critical to achieving their growth goals (80 percent versus 30 percent). Given leaders strong growth since 2011, it is perhaps not surprising that three-fourths of leaders (versus onefourth of others) increased their capacity by at least 20 percent during that time. Some of that increase can be attributed to leaders opening of new facilities (discussed below). However, its reasonable to surmise that leaders significant boost in labor efficiency, combined with greater operational efficiency resulting from initiatives they are undertaking to improve the reliability and productivity of existing assets, has been responsible for creating additional capacity in facilities already on line. Interestingly, leaders top revenue markets did not differ dramatically from those of other manufacturers, suggesting leaders performance advantage is due not so much from where they get
their sales, but how they operate. In fact, a closer look at our data revealed that leaders tend to differ substantially from other manufacturers in a number of key areas.
Facility location
According to our analysis, leaders are more active in making changes to their production facility networkwhether it is in relocating plants or starting new ones. For instance, leaders are twice as likely (Figure 21) to have relocated manufacturing operations since 2011, and did so for two primary reasons: to enter a new market and to improve quality. Conversely, non-leaders decisions were driven primarily by cost factorsa desire to reduce transportation and labor costswhich were far less a concern for leaders. In the coming year, leaders appear likely to outpace non-leaders in relocations as well, with 70 percent of the former versus 34 percent of the latter indicating they are considering relocating manufacturing operations in 2013 and 2014. Similarly, leaders were about twice as likely as others to have started new operations since 2011 (Figure 22), with Brazil and China also the most popular locations for these new facilities among leaders. Leaders also favored North America for new operations,
Figure 21: Percentage of companies having relocated manufacturing operations since 2011.
Yes No Not sure 5% 15% 39% 57% 80%
4% Others
Leaders
Figure 22: Percentage of companies having started new manufacturing operations since 2011.
Yes No Not sure 10% 5% 2% Leaders Others 46% 52% 85%
Manufacturing Leaders 28
How a CoNtrol TowEr CaN HElp MaNufacturErS MakE BEttEr ProDuctioN NEtwork DEciSioNS
By Jose Bleda, Managing Director, Accenture Management Consulting
Global manufacturers today face a number of significant challenges in managing their supply chains. One of the biggest is deciding how to best leverage resources across their production network to help meet changing demand, increase competitiveness, and support the companys growth agenda. The challenge is especially difficult given three factors: manufacturers large, complex networks that often include many external entities such as contract manufacturers and logistics services providers; the large amounts of data manufacturers must sort through; and the economic and market volatility that require manufacturers to react more quickly or even anticipate problems before they occur. Perhaps the biggest impediment to making such resource-balancing decisions is a lack of visibility into the state of the network. As our survey found, only 29 percent of executives strongly agreed that their company has full visibility into its networks operations that enables it to effectively manage the network and make appropriate decisions to balance demand and capacity. Recognizing their challenges, leading organizations are embracing the concept of a control tower to help them more effectively leverage their network and, in turn, reduce costs, improve product availability, optimize working capital, and mitigate the risks of manufacturing network disruptions. The concept of a control tower is not new: A number of influential organizations have implemented control towers to help improve transportation and distribution. A major technology company, for example, has used its version of a control tower, called the Global Command Center, to coordinate parts logistics and field technicians to respond swiftly to customers requests, while a leading consumer goods manufacturer relies on a control tower to help it manage logistics in emerging markets by providing visibility into inbound and outbound distribution flows. By extending the control tower concept to the entire supply chainand, specifically, manufacturinga company can gain integrated visibility across all dimensions of the network, including demand, capacity (supplier, manufacturing, and distribution), inventory, orders/shipments in transit, and logistics partners. It also can use the control tower to conduct predictive analytics to make sense of the data it collects to trigger alerts, detect tipping points, run what if analyses of scenarios to model the outcome of potential decisions and, ultimately, initiate appropriate action. A control tower can also help enable a manufacturer to monitor the execution of supply chain activities, and alert one part of the supply chain when it will be impacted by anotherfor example, predicting raw material shortages and reallocating production and inventory accordingly. And, increasingly control towers are being used to help orchestrate the work of shared service centersenabling a super back office to optomize business process, IT investment and execution skills synergies across businesses and geographies. Control towers can take different forms (depending, for instance, on functional footprint or scope of control). However, all control towers generally need a few key common elements to be successful: Connection to suppliers and other trading partners (and their suppliers) to eliminate visibility gaps that create blind spots and can undermine the quality of the insights generated Built-for-purpose technology that complements, rather than replaces, typical transactional systemsi.e., systems of engagement versus systems of record High-quality data, which typically requires an industrialized master data management capability to ensure all systems are in synch An analytical capability to be able to identify potential issues (predictively) by modeling what if? scenarios and facilitating decision making. Sufficient organizational weight to be able to influence execution across both long-term and short-term horizons While many companies have used control towers in a more focused way, historically the barriers to establishing a broader manufacturing network control tower have been high and difficult to overcome. These include a high initial investment for the necessary technologies and facilities, a complex integration effort to tie into all relevant systems, long lead times to operationalize, and the difficulty and high cost associated with maintaining the capability (especially, technology upgrades and attracting and retaining the people to run it). However, that is changing quickly, as advances in technology (such as cloud and SaaS models) can make integration efforts easier and a growing number of providers delivering some or all control tower functions as a service can substantially reduce the time and cost associated with deploying and maintaining the capability. With manufacturers continuing to expand their operations around the world and increasing the complexity of their production networks, the traditional supply chain integration/optimization approach is not enough. A control tower is fast becoming an indispensible capability in the pursuit of growth in a volatile global economy.
29 Manufacturing Leaders
Manufacturing Leaders 30
with 35 percent reporting having opened new facilities in the United States and 24 percent in Canada. For non-leaders, China, Brazil and the United States were also the top three locations for new plants. Entrance into a new market was also leaders top reason for starting a new facility, but the desire to reduce transportation costs was seen as nearly equally important. Non-leaders efforts to start new facilities were largely driven by the need to reduce labor costs and to support the entrance into a new market. Contract manufacturing also appears set to play a greater role among leaders than nonleaders. In fact, 70 percent of leaders (and just 22 percent of non-leaders) said they plan to extensively increase their use of contract manufacturing in 2013 and 2014. Leaders are more likely than others to view contract manufacturing as part of their long-term strategy rather than as a way to relieve shortterm capacity constraints (the reason that was cited by a majority of non-leaders).
Operating model
As mentioned earlier, leaders are far more likely than non-leaders to be convinced of the value of flexible operations to achieving their growth goals. And it also appears that leaders operating model is better suited to supporting such flexibility: Leaders were more likely than others to say that all six dimensions of their operating model very effectively accommodate the dynamic shifting of production within a facility or across the facility network in response to demand (Figures 23 and 24). In Accentures experience, that means leaders typically have a high degree of consistency and standardization across their operating model, which can help enable leaders to quickly and easily move production within and across any of its plants when necessary. Leaders also appear to be more advanced than others in key capabilities that are critical to operating more flexibly and dynamically (Figure 25). They are about twice as likely to strongly agree their company has a
good understanding of the local cultural differences and needs in its most important revenue markets; is highly adept at accurately sensing market changes or opportunities before competitors do; has full visibility into its networks operations that enables it to effectively manage the network and make appropriate decisions to balance demand and capacity; and extensively employs modular and consistent business processes and policies that enable it to quickly and dynamically allocate product design and manufacturing capacity across the facility network (including contract manufacturers) in response to changes in its markets. However, leaders are not complacent. In fact, just the opposite is true: Eighty-five percent of leadersand just 24 percent of nonleadersconsider improving their operating model a very significant priority. Leaders are more likely than non-leaders to be investing in improving all six dimensions of their operating model in 2013 and 2014, especially talent and organization structure.
31 Manufacturing Leaders
Figure 23: How effectively manufacturers operating model accommodates the dynamic shifting of production across the facility network.
Production facility network Information technology applications Information technology infrastructure Business processes, policies, and capabilities Talent / skills base Organization structure and incentives system Leaders 16% 21% 17% 23% 18% 24% Others 35% 60% 25% 50% 50% 50%
Figure 24: How effectively manufacturers operating model accommodates the dynamic shifting of production within a location.
Production facility network Information technology applications Information technology infrastructure Business processes, policies, and capabilities Talent / skills base Organization structure and incentives system Leaders 17% 22% 23% 24% 17% 26% Others 50% 45% 50% 50% 50% 60%
Figure 25: Extent to which manufacturers agree with the following statements.
We extensively employ modular and consistent business processes and policies that enable us to quickly and dynamically allocate product design and manufacturing capacity across our facility network We have full visibility into out networks operations that enables us to effectively manage the network and make appropriate decisions to balance demand and capacity We are highly adept at accurately sensing market changes or opportunities before competitors do 23% 55%
28%
40%
22%
50%
We have a good understanding of local cultural differences and needs in our most important revenue markets
80%
Manufacturing Leaders 32
Digital Factory
Digital technologies are transforming the ways in which manufacturers design and operate their plants and the assets within them to drive efficiencies. For instance, leading companies are deploying technology solutions that support the plants manufacturing process, layout, operations and specialized areas like FMEA quality control activities. By leveraging simulation technology, companies are more accurately planning resources, buffer requirements,
33 Manufacturing Leaders
Manufacturing Leaders 34
Talent
Leaders are focused on building a strong talent base to help them succeed yet, because they value talent so highly, they are more likely to be critical of the skills they have in house and wary of possible talent shortages that could hamper their efforts to grow. For instance, leaders are twice as likely as other manufacturers to strongly agree that their talent strategy enables them to acquire or build the skills they need to compete effectively (70 percent versus 35 percent), and nine times more likely to say they increased their manufacturing workforce substantially since 2011 (75 percent versus 8 percent)with most leaders saying people hired were in countries where demand is strongest (79 percent) or have skills that are strategically important to the company (68 percent). On the other hand, because the performance baras well as the needamong leaders is high, leaders also have major concerns about talent. They were consistently more likely than other manufacturers to say they have extensive skills gaps across all workforce roles (Figure 26), and they were more than twice as likely (35 percent versus 13 percent) to cite the aging workforce or shortage of talent as a factor that could impede their ability to achieve their growth goals. That is why leaders are intent to remain voracious acquirers of talent. They are 12 times more likely than other companies in our study to say they will increase their overall manufacturing workforce by more than 20 percent in 2013 and 2014 (60 percent versus
5 percent) and, in doing so, a large majority anticipate capitalizing on all types of workers: full- and part-time employees, contractors and consultants (Figure 27). And regardless of what type of worker they are hiring, leaders recognize that if they want quality, they have to pay for it. For example, while leaders were similar to others in most of the major skills challenges they said they encounter across all workforce roles, they did differ substantially in one area: Leaders were consistently far less likely than other manufacturers to say they lacked skills in a particular workforce because they couldnt pay what workers demand. Furthermore, leaders were more than twice as likely as others to say they offer competitive salaries and benefits to close their skills gaps.
preferred means for extending asset life (Figure 29). Leaders also are twice as likely as others to say they are investing in operations analytics to help improve the efficiency and productivity of individual manufacturing facilities (Figure 30). The clear message is that manufacturing leaders are increasingly focusing on making their assets more reliable and responsive, which in turn can boost labor efficiency and support a more flexible and dynamic facility network that helps enable leaders to more easily adapt to changing market conditions. Finally, leaders appear more focused on strengthening their information technology base in the coming year as they intensify their efforts to become a digital business. All but one said they are planning to invest in IT applications in the next 12 months, compared with 76 percent of non-leaders. The majority of leaders expect to direct those IT investments toward ERP solutions (58 percent) and performance management tools (58 percent), while 47 percent plan to invest in computerized maintenance management systems.
Investments
All of the leaders in our study, and threefourths of the non-leaders, said they made manufacturing capital investments since 2011. Leaders were somewhat more likely than others to direct those investments toward new plant construction and manufacturing technology. Going forward, leaders appear to be more focused on making capital investment in new plants and technology once again, but also in manufacturing equipment and existing plant infrastructure (Figure 28). Leaders also signaled a greater interest in getting more out of what they already have. Half of leaders, compared with 21 percent of non-leaders, said they are concerned with extending the life and contribution of existing assetswith the vast majority of leaders citing total productive maintenance as their
Figure 26: Percentage of manufacturers reporting they have significant skills gaps in these workforces.
Maintenance Skilled trades labor General labor Supervisors Operations management Executives Leaders 6% 12% 12% 10% 7% 10% Others 20% 30% 25% 35% 32% 35%
35 Manufacturing Leaders
Figure 27: Percentage of manufacturers planning to increase various types of workforces in 2013-14.
Full-time employees Part-time employees Contractors Consultants Leaders 47% 30% 37% 26% Others 65% 70% 70% 90%
Figure 29: Initiatives manufacturers are pursuing to extend the life and contributions of existing assets.
Applying total productive maintenance (TPM) Applying lean principles to reduce waste Applying automation technology Applying analytic Leaders 38% Others 46% 54% 54% 68% 92%
48% 19%
Figure 30: Initiatives in which manufacturers plan to invest to improve plant efficiency and productivity.
Operations analytics Lean transformation Factory flow optimization Inventory management & control Quality management Plant asset reliability Production planning Energy management Environmental health & safety Leaders 10% 10% Others 20% 18% 18% 15% 20% 25% 20% 26% 25% 37% 40% 32% 45% 45% 43% 50%
Manufacturing Leaders 36
37 Manufacturing Leaders
Top 10
Manufacturing Leaders 38
are thinking about sustainability in a much broader way. They are making conscious choices and are implementing green policies that help enable innovation through initiatives such as resource efficiency, closed-loop processes, and robust EHS systems. For instance, if they are building a greenfield plant, should they pursue LEED certification or create a living building? What options do they have in terms of lighting, heating, energy, construction methods, and water that could help them offset the cost of a new plant to effectively make the facility cost neutral? Many manufacturers also have become huge advocates and practitioners of recyclingnot only to support their efficiency push, but also for commodity assurance, something that is especially important as prices rise on key commodities or as competition increases and causes supply shortages. The companies on the leading edge of sustainability have gone even further, and are now thinking about all things operational being inherently valuable to the sustainability agenda. They see that every operational efficiency play or risk mitigation initiative can have a sustainability impact. They recognize that sustainability can actually help increase revenue. They know that customers value it and are often willing to pay more for products that are sustainably produced. They see the impact sustainability can have on their ability to enhance their brand and image, engage with customers, and recruit and keep the best and brightest talent. They proactively look at how to design sustainability into their products from the beginningfor instance, eliminating from product designs or packaging certain components or materials that cant be recycled or are harmful to the environment. As they continue their sustainability journey, or look to begin it, manufacturers should keep in mind three elements that can be critical to help position a sustainability agenda for success.
The first is data. Manufacturers must collect the right data on sustainability initiatives (both internal and among suppliers). With that data, a manufacturer can determine the extent of the opportunity possible, set desired targets for its sustainability initiative, and define the right metrics that will gauge progress and return on investment (which, in our experience, has consistently been a six- to 18-month payback). The second element is process. Manufacturers can make one-off decisions based on the data they collect, but until those decisions are institutionalized, the company cant count on repeating its results year after year. Thus, sustainable practices should become part of the fabric of how the company does business, which typically requires the creation of multiple cross-functional processes. Finally, effective sustainability practices typically require governance. Change management is the key here. The decision to pursue a sustainability agenda should flow from the top, and be a part of the formal objectives of employees. A company should must have formal sustainability policies and procedures, clearly defined responsibilities and accountability for making sustainability happen, and ongoing monitoring, tracking and reporting of progress. The most innovative manufacturers recognize that the best sustainability initiatives typically involve four dimensions: cost reduction, revenue generation, brand enhancement, and risk reduction. For these companies, sustainability is no longer just something to pursue because regulations require it or its the right thing to do but, rather, because sustainability has a strong business case and, thus, has truly become a business imperative.
Manufacturing Leaders 40
CoNcluSioN
While its true that the global economy overall has improved in the years since the recession, improvement certainly has not been geographically equitable. Most European economies are still struggling to find their footing, while demand in emerging markets continues to expand (albeit more slowly than their blistering pace of recent times) and North America seems to have finally turned the corner. Yet even in the face of hard facts, many observers still find it difficult to come to a consensus of where the global economy is headed in the next few years, let alone the next 10 or 15. Given the ongoing uncertainty and volatility inherent in todays economic conditions, manufacturers must be ready for whatever is thrown at them. And that can mean infusing greater flexibility into their operating model, production network and talent base to better enable them to respond to the sudden swings in marketplace and economic conditions that are the hallmark of the business environment today. Indeed, as the manufacturing leaders we profiled in our study have demonstrated, such flexibility can help position manufacturers to grow more strongly, post higher margins, increase production (often without buying or building new facilities), and improve the efficiency of their workforce. By being able to, for instance, dynamically shift production within a facility or across the facility network in response to demand, these leaders are less vulnerable to downward swings in some markets and better positioned to capitalize on new opportunities in others. This, in turn, can help them put even more distance from less-able competitors that are left scrambling to figure out how to align their operations with unforeseen changes. Furthermore, as leaders demonstrated, people remain key to competitive advantage. While its tempting to put the brakes on hiring during uncertain times, leaders maintain their focus on attracting and cultivating the skills they need to stay ahead of the game. And that typically can require not only paying the going rate for top talent, but also using innovative approaches such as learning academies to close skills gaps in critical workforces. Finally, manufacturers should actively consider ways to improve the reliability and productivity of the assets they already have to help boost capacity, instead of defaulting to buying or building new. Tools such as total productive maintenance and operations analytics, favored by the manufacturers in our study, can help extend the life of facilities and equipment and make them more responsive to the needs of the business. In summary, the overriding message from our research is clear: Manufacturers that plan to grow this year and in the years ahead must be able to move quickly, confidently and cost-effectively to capture growth opportunities that present themselves in an unpredictable global economy.
41 Conclusion
AppENDiX
Methodology and Demographics
In May and June 2013, Accenture embarked on a research initiative designed to shed light on the factors shaping manufacturing in todays environment, as well as how manufacturers are refining their manufacturing strategy and operations to remain successful. The study consisted of a web-based survey of 250 senior manufacturing executives (Figure 31) in companies headquartered in North America, Europe, South America and Asia. These companies have global operations and annual revenues that range from $500 million to more than $50 billion. Participating companies represented six main industry sectors: automotive, consumer products, industrial equipment, electronics and high tech, oil and gas, and chemicals and natural resources (Figure 32). Figure 31: Participating executives titles.
Job Title
Managing Director, Senior Director, or Director C-Level executive (e.g. CEO, CFO, COO, CTO, CMO, CRO) Senior Vice President, Executive Vice President, or Vice President Total
Count
107 91
Percent
43% 36%
52 250
21% 100%
Industry
Industrial Equipment Electronics and High Technology Consumer Products Automotive Chemicals and Natural Resources Oil and Gas Total
Count
49 48 44 39 36 34 250
Percent
20% 19% 18% 16% 14% 14% 100%
Appendix 42
About Accenture
Accenture is a global management consulting, technology services and outsourcing company, with approximately 275,000 people serving clients in more than 120 countries. Combining unparalleled experience, comprehensive capabilities across all industries and business functions, and extensive research on the worlds most successful companies, Accenture collaborates with clients to help them become high-performance businesses and governments. The company generated net revenues of US$28.6 billion for the fiscal year ended Aug. 31, 2013. Its home page is www.accenture.com.
This document is intended for general informational purposes only and does not take into account the readers specific circumstances, and may not reflect the most current developments. Accenture disclaims, to the fullest extent permitted by applicable law, any and all liability for the accuracy and completeness of the information in this document and for any acts or omissions made based on such information. Accenture does not provide legal, regulatory, audit, or tax advice. Readers are responsible for obtaining such advice from their own legal counsel or other licensed professionals.
Copyright 2013 Accenture All rights reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture.
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