Ceramic Sanitaryware Manufacturing Benchmark Report Free Version 2016

1. MWWB Global Ceramic Sanitaryware
Benchmarking Report
2016 Introduction Report

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Summary
Welcome to the 2016 free introductory MWWB Global Sanitaryware Benchmarking Report.
This report is produced annually and contains some of the data from all of the factories that
participated in the exercise over the past 12 months. If you want more information
concerning the complete versions of the report and you would like your factory to be
included this year, then please contact us through benchmarking@mwwb.eu or read the
sections at the end of the report about how to get involved.
Why Benchmark?
There are many reasons to get involved in a benchmarking exercise, from the simple “How
are we doing?” to the more complex “Looking for ideas” through to the “we want to know
we are truly world class”. MWWB believes that it should be at the heart of your continuous
improvement effort. Every company is trying to get better every day; to beat the
competition you have to get better faster than them and benchmarking will help you see if
you are succeeding and where the best opportunities remain.

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Only partial information is included in this free report. For some KPIs the whole data set is
reported, for others only some points and for others none at all. To get access to the whole
data set you must sign up to the full report and supply data for your factory where
applicable. Access to the full report also gives you further information about exactly how
the data is calculated and what is included. It also gives you the opportunity to get involved
in including additional features in the report and requesting new benchmarking options.
All data is presented anonymously. Each factory is given a six-digit code which follows it
through the process. In some cases, it is actually illegal to share this data without making it
anonymous and we believe in any case that factories prefer not to directly share this kind of
data.
Clay Loss Average Clay loss was 7.90% and ranged from 1.1% to 14.8%. Clay loss is
calculated by simply dividing the reported losses by the total cast volume so it
is possible that actual losses are higher due to underreporting.
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
291846 938367 741019 144814 225813 398783 394707 394816 270821 397091 889978 941444
Clay Loss

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Once Fired Loss Average Once Fired loss was 7.17% and ranged from 2.2% to 12.9%.
Once Fired loss is calculated by simply dividing the reported losses by the total
once fired volume so again it is possible that actual losses are higher due to
underreporting.
Unrecorded Loss Unrecorded loss represents the difference between the recorded
losses and the theoretical losses considering the cast volume and warehouse
in. Most factories recorded under 5% unrecorded loss with some effectively at
0 but one factory had almost 10%.
Work in Progress Ideally a factory will carry as little WIP as possible. The best factory in
the exercise carries less than 1 week of WIP, the worst more than 4 weeks. 2
was a typical value.
Labour Efficiency The main report calculates Efficiency by both weight and pieces, here
the calculation is presented only for pieces. The calculation is how many hours of total
labour input are required to make one piece. The best factory made a piece every 22
minutes. The full report breaks this down into Direct and Indirect labour.
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
397091 398783 225813 938367 394816 394707 741019 291846 144814 889978 270821 941444
Once Fired Loss
-
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
938367 291846 398783 741019 144814 397091 270821 225813 889978 394816 941444 394707
Piece Productivity

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Global Yield The best factory in the group had a global yield of over 92%. For every 100
pieces cast it sent more than 92 to the warehouse.
Right First Time The best factory in the group had a Best First Time of almost 86%. For
every 100 pieces cast 86 went to the warehouse without any repair work.
Coming Soon
Energy Efficiency Following requests from some of the participating companies we are
now also tracking total energy consumption by site and will include measures
on consumption by piece and by weight.
Also in the Main report
More factories Companies purchasing any of the full reports get quarterly updates
including details of all new factories added in the last Quarter.
Process details Factories are flagged according to production methods and materials
used giving you insights as to how much changing your casting methods might
help you.
Improvement methodologies We ask all the participants what type of improvement
processes they are currently using in their factories, 5S, six sigma, lean etc
helping you to understand better what might help you
Further statistical and graphical analysis Powerful and detailed analysis exploring
relationships between yield and productivity highlighting the impact of
measures taken and other factors such as factory size and location.
Information presented in easy to access formats.
And whatever you want Participate in the exercise and let us know what YOU want
included. Please bear in mind that all your data is completely anonymous so
anything that could help to identify a factory will NEVER be included. As a
result of requests we are starting to track energy usage

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How to get the Main Report
There are three methods to gain access to the main report depending on your status and
requirements.
Basic Report Currently reduced to €1000 – normal price €1500
The basic report includes everything above, but completes it with a full report with all the
graphics and data for all the factories as well as additional graphs, data and analysis. It also
includes quarterly updates and an opportunity to make proposals to improve and change
the data collection and analysis. You will also receive the MWWB benchmark manual that
explains in greater detail how the analysis is carried out and the significance of some of the
chosen data sets. All you need to do is read the data anonymity pages that follow and
complete the data request over the next few pages and return it to benchmark@mwwb.eu
Plus Report Currently reduced to €3000 – normal price €5000
The plus report includes everything above but also pays for a factory visit at no further cost.
During the factory visit all of the normal data will be audited but there will also be additional
data collection covering topics such as raw material stocks, kiln energy efficiency and
departmental operational efficiencies. These types of data are too difficult and unreliable to
collect by questionnaire. It may not always be possible to provide benchmark comparisons
for all of these additional data sets but where this is possible it will be completed as part of
a more detailed report. As part of the visit we will also complete a Value Stream Map for
one of your key products. This is a key tool to use as part of your ongoing improvement
process.
Corporate Report Contact us for details
If you have more than one factory we would be delighted to discuss your specific needs and
arrange an appropriate package for the work. We normally recommend a mixture of visits
and questionnaires, depending on the sites and your particular needs. In addition, if you
have a company specific method for calculating certain KPIs we can use our existing raw
data sets to calculate these company specific KPIs. We will of course still provide you with
the standard reports as outlined above.

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How we protect your data
Please read the following carefully. By placing an order for a copy of the Report you are
considered to understand and agree with the following policy.
The information provided will be used only for the purposes of the Benchmarking Exercise
and never in ways that will reveal who you are. You choose an identification number that
will be used to designate your data both internally within MWWB and also externally in our
reports. You will not be identified in any report from this study.
In addition, your raw data, the numbers you supply and/or we collect, will never be
published in any form, even anonymously, nor will it be shared with anyone outside of
MWWB. MWWB only publishes aggregated data calculated from the raw data that you have
supplied.
By requesting and ordering a copy of the main report you must supply at least the main data
that MWWB needs. We will never supply the main report to a Ceramic Sanitaryware
manufacturer who have not chosen to provide data for the Benchmarking Exercise.

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Factory Reference Your choice of 6 digit reference
Company Name
Site Name
Country
Start Date Normally we review data over a 12-month period but you are welcome to
define your own start and end dates
End Date
Cast Volume
pieces
A piece is any large single piece that is sold as a single ceramic unit and/or
can be replaced independently. It does not include accessories.
Pieces would therefore include toilets, washbasins, bidets, tanks,
pedestals, semi-pedestals, shower trays, kitchen sinks and one piece
toilets. It does not include shelves, tank lids, toilet-roll holders or other
accessories. If you have any doubts, please contact us for clarification.
It is important that this definition is applied throughout the process. For
instance, some one piece toilets may be cast using two, three or even
more castings joined together. As far as this report is concerned these
pieces are considered to be one cast piece.
Cast Losses
pieces
How many pieces are recorded lost in casting, drying or glazing?
Once Fire Volume
pieces
How many pieces do you put in the once fire kiln?
Once Fire Losses
pieces
How many pieces are recorded as lost (scrapped) after once firing
Refire Volume
pieces
How many pieces go into the refire kiln, either from once fire or from
refire
Refire Losses
pieces
How many pieces are recorded as lost (scrapped) after refiring
Other Losses
pieces
Any other recorded losses such as transport losses or other corrections
Unfired WIP period
start pieces
How many pieces of Work in Progress are there that have not left the kiln?
This includes pieces still in the kiln or those that have left but not yet been
sorted. All pieces must be included that are not recorded already as losses.
Unfired WIP period
end pieces
How many pieces of Work in Progress are there that have not left the kiln?
This includes pieces still in the kiln or those that have left but not yet been
sorted. All pieces must be included that are not recorded already as losses.
Fired WIP period
start pieces
How many pieces of Work in Progress are there that have left the once fire
kiln? This includes pieces in refire or cold repair processes but excludes
pieces recorded as good and transferred to the warehouse. All pieces must
be included that are not recorded already as losses.
Fired WIP period
end pieces
How many pieces of Work in Progress are there that have left the once fire
kiln? This includes pieces in refire or cold repair processes but excludes
pieces recorded as good and transferred to the warehouse. All pieces must
be included that are not recorded already as losses.
Once Fire Good
pieces
How many pieces are recorded as good coming directly out of the Once
Fire Kiln? This includes pieces requiring minor cold repairs or grinding but
excludes pieces needing refire operations.
Refire Good
pieces
How many pieces are recorded as good coming out of the Refire Kiln? This
includes pieces requiring minor cold repairs or grinding but excludes pieces
needing further refire operations.
Total Labour Hours
Hours
How many hours of labour were used in the factory during the time
period, this includes both direct and indirect labour including managers. It
should exclude any warehouse or sales staff.
Weight of good
product
Total weight of all good product transferred to the warehouse. Please
indicate chosen units carefully.
Total Energy
Consumption
Total Energy used within the factory from any source such as gas,
electricity, heated water, other fuels. Please indicate chosen units carefully

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Factory Type and Improvement tools
What Percentage of your cast volume is
pressure cast in resin moulds?
To the nearest 5%
What Percentage of your production is fired in
intermittent kilns?
To the nearest 5%
What Percentage of your production is NOT
Standard Vitreous China?
To the nearest 5%
What Percentage of your glazing is done by
robot?
To the nearest 5%
What Percentage of your glazing is not white? To the nearest 5%
How many different cast models do you have
in your factory?
What type of fuel do you use in your main
kiln?
Do you use 5S? Yes/No
Do you use 6 sigma? Yes/No
Have you used consultants in the last 3 years? Yes/No
Do you apply Lean Methods? Yes/No
What other improvement methods have you
used in the past 3 years
Please list
Please include a Purchase Order for the relevant amount so that we
can process your order and data.

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Making Work Work Better
MWWB are a specialist consultancy focussed on helping companies develop and implement
Operational Strategies. They stand by you through every step of the process from analysis of
your existing situation, using tools such as Benchmarking and Value Stream Mapping,
through development of a new strategic plan and integration with corporate strategy, right
through to implementation.
They have experience in many different industries from food and drink, through textiles and
plastics, right up to automotive, as well as retail. Whatever your situation MWWB can help
to Make your Work Work Better.
For more information about how MWWB can help you work better contact us here
info@mwwb.eu
Barry Crisp
Barry Crisp is Founder and Managing Consultant of MWWB. After a career of more than 25
years in many different industries and working across 5 continents in a variety of senior
roles he now runs MWWB and is based in France. With Degrees in Engineering and
Management from Durham and Cambridge Universities and an MBA from Warwick Business
School he backs up his practical experience with a thorough technical background. He
started the benchmarking practice in MWWB and at the end of 2015 introduced the Global
Sanitaryware Benchmarking exercise and is now developing it for other industries.
Contact him at barry@mwwb.eu