Benchmarking Best Practices: An Integrated Approach: Khurrum S. Bhutta and Faizul Huq
Benchmarking Best Practices: An Integrated Approach: Khurrum S. Bhutta and Faizul Huq
I. Introduction
The essence of benchmarking is the process of identifying the highest
standards of excellence for products, services, or processes, and then making
the improvements necessary to reach those standards ± commonly called ``best
practices''. The justification lies partly in the question, Why re-invent the
wheel? Benchmarking is not just competitive analysis or number crunching,
nor is it spying, espionage or stealing. It is a process to establish the ground for
creative breakthroughs. Many organizations publicize what they have
achieved, but it is unusual for them to be open on the more mundane facts of
how this transformation was made to work. More than 70 percent of the
Fortune 500 companies use benchmarking on a regular basis, including AT&T,
Ford, Eastman Kodak, IBM, Ford Motor Company and Weyerhaeuser
(Greengard, 1995).
Benchmarking is a way to move away from tradition. It carefully dissects
the organization into segments, and then removes and inserts pieces to account
for changing environments. Changes occur once the process has started, and
will continue to change and mold the organization for as long as individuals are
continuously striving to make it better. If these individuals lose the ability to
analyze and make changes, they begin to lose ground. Benchmarking was
traditionally used as a problem solving technique (problem based
benchmarking). During the past several years, through extensive efforts,
leading organizations have come to realize that there is a better way to focus
benchmarking activities for greater payback. The most effective vehicle to
ensure continuous improvement is to focus on the basic processes that run the
organization. It is this concentration that will deliver the outputs that will
achieve the organization's objectives, priorities, and mission. This (process
based benchmarking) is a new and revolutionary perspective in benchmarking.
Benchmarking: An International
When undertaking a literature review in the benchmarking area, one is
Journal, Vol. 6 No. 3, 1999,
pp. 254-268. # MCB University
intimidated by the numerous methods adopted to do what actually accounts to
Press, 1463-5771 the same thing. A gap seems to exist in the literature regarding a unified
understanding of the steps involved in a benchmarking study. This paper will Benchmarking ±
attempt to fill this gap with the help of case studies. This paper is structured in best practices
six sections. In the first section an introduction to benchmarking is presented to
followed by a review of the current literature; the third section touches on the
types of benchmarking and an integrated approach is laid out; section four
enumerates case studies with the fifth section concentrating on the contrasts
between Xerox and Kodak approaches to benchmarking. Section six lists the 255
conclusions of the paper. The paper is concluded with a discussion to facilitate
the understanding of the subtle differences in the benchmarking methods/
techniques of the companies studied and some misconceptions among
executives about benchmarking.
Performance ∇ Φ ∇ θ
Benchmarking
Process ∇ θ Φ Φ
Benchmarking
Strategic θ Φ θ θ
Benchmarking
Figure 1.
Relevance/Value High Φ Medium ∇ Low θ The benchmarking
matrix
Source: Adapted from Leibfried & Mcnair (1992)
258
Collect and analyze
Benchmarking information Form a Benchmarking team
Identify Benchmarking
Partners
Figure 2.
The benchmarking
wheel
Source: Adapted from Camp (1989)
Figure 3.
Relationships of the TIME
benchmarking steps
Source: Adopted from Feigenbum (1951)
Following are two case studies of leading international firms who have adopted
the benchmarking approach to their activities.
IV.I Xerox
Xerox's success is the first in the history of benchmarking. It has become a real
model since, being in a critical situation in 1972, Xerox has achieved what is
called today a top-benchmarking partner status. In 1979, Xerox started
benchmarking and by 1989, had won the Malcolm Baldrige National Quality
Award (Boxwell, 1994). The Xerox benchmarking methodology was a ten-step
process (Camp, 1989).
Step I: identify what is to be benchmarked. Xerox's benchmarking process
first started in the photocopier manufacturing unit as part of an effort to assess
its manufacturing costs. Benchmarking was in effect invented in the late 1970s,
when a shocked Xerox decided to analyze the performance of its Japanese
associate to discover how Eastern rivals could sell excellent photocopiers for
less than it cost the parent to make them.
Step II: identify comparative companies. Xerox first studied one of its
Japanese affiliates, Fuji-Xerox, and later on Canon, Minolta and Toyota to
determine whether the relative costs of their Japanese counterparts were as low
as their relative prices (Finnigan, 1996).
Step III: determine data collection method and collect data. The studies confirmed
that US prices were higher than the Japanese ones. Japanese costs became the target
for Xerox. However, the benchmarking process was only starting. Managers from
the main plant visited Xerox's Japanese affiliates and saw what they were doing at
the factory floor. Xerox then started collecting the information.
Step IV: determine current performance gap. The information collected at
the previous step is then used to determine the gap that might exist between
Xerox's performance and the best in class.
Step V: project future performance levels. From the gap analysis, projected
future performance levels are determine and how these levels are going to be
achieved and maintained is determined.
Step VI: communicate benchmark findings and gain acceptance. All Xerox
employees receive at least the basic 28-hour leadership through quality training
and many were trained in advanced quality techniques. Over the last four years, Benchmarking ±
Xerox has invested four million man-hours and $125 million in its training best practices
program. Once a new benchmark has been established and incorporated for in
future strategy, it is communicated to the rest of the organization so that others
may also use it in their standard operating procedures.
Step VII: establish functional goals. Xerox identified that purchased
materials accounting for 70 percent of its product unit manufacturing costs,
261
small strides could translate into significant quantifiable benefits. The
company cut its supplier base from more than 5,000 in the early 1980s to 420
today. Defective components have been reduced from about 10,000 parts per
million in 1980 to 225 today. Six of seven parts inspectors have been reassigned
to other jobs, and 95 percent of supplied parts need not be inspected at all.
Component lead-time is down from 39 weeks in 1980 to eight weeks last year.
And the cost of purchased parts has been slashed by 45 percent. These goals
were not necessarily all set at once but with the continuous process put in place
for lowering costs they came more easily and without disruption.
Step VIII: develop action plans. Concrete action plans need to be developed
and Xerox developed these plans, resulting in the reduction in lead times and
the quality improvement of the copiers.
Step IX: implement specific actions and monitor results. Benchmarking has to
be a coordinated plan. Specific action plans have to be drawn up and the results
monitored to ensure that the required results are being achieved.
Step X: recalibrate benchmarks. After having benchmarked Japanese
industries, Xerox didn't stop there, it started looking at L.L Bean, the American
Hospital Supply and Caterpillar. The results speak for themselves as Xerox is
the only company in the world to have won all three major awards: Japan's
Deming Prize, America's Malcolm Baldrige National Quality Award and the
European Quality Award. Obviously, adopting the benchmarking process was
essential (Finnigan, 1996).
IV.II Kodak
The legal department may be more prestigious and the advertising department
may be sexier, but the maintenance department is one of the unsung heroes of a
manufacturing company. Neglect maintenance of the myriad pieces of
equipment in a factory and someday soon the company will be devoting more
time to the emergency repair of machinery than to the production of goods
(Geber, 1994). Kodak uses a six-step benchmarking process. The following is a
description of benchmarking at Kodak's Rochester plant.
Step I: what to benchmark. There is no guessing about the impact of a poorly
performing maintenance department on a company's fortunes. If a machine
breaks down in the middle of a run, it is easy enough to measure how many
widgets its operator would have produced during the idle time.
BIJ That ability to measure most aspects of maintenance performance, along
6,3 with a desire to lessen the maintenance department's drag on earnings, led the
maintenance function at Rochester, NY-based Eastman Kodak Company to
begin a benchmarking project in 1991.
As a large company with worldwide locations, Kodak had the luxury of
measuring all its maintenance divisions against each other internally as it tried
262 to find the exemplars for each of a long list of measurements. It then compared
the various results to those of other companies with superior maintenance
departments. As a result, Eastman Kodak was able to increase its planned
maintenance work, reduce its inventory of parts for maintenance, and reduce
the amount of time it spent on emergency repairs. Each one of those outcomes
had an effect on the company's earnings.
Step II: establish teams. In 1990, the company's quality improvement director
formalized ad hoc approaches to benchmarking by establishing the three-
person office under Mr Enustun. Besides acting as a port of entry for incoming
benchmarking requests from other companies, Mr Enustun's office maintained
a detailed internal database that described and quantified best practices within
Kodak worldwide. In addition, he and his staff served as consultants for
benchmarking projects undertaken throughout the company. In that role, they
helped Harvey Berson get his project started in January 1992.
Berson, manager of Kodak's manufacturing engineering and maintenance
organization, oversaw maintenance of the equipment the company used for
film production in nine manufacturing plants scattered across the globe.
Berson wanted to find the pockets of excellence around the world and bring the
rest of the maintenance departments up to those standards, thereby reducing
overall maintenance costs for the company.
Step III: identify partners and identify critical measures. Berson knew that
some maintenance facilities within Kodak were doing much better on certain
measures than Kodak-Park, the company's huge hometown facility in
Rochester. He was determined to improve Kodak-Park's performance, while
seeking top performers elsewhere within the company. Luckily for the
benchmarking project, the maintenance function was easily tracked and
measured. One of the first tasks for Berson and the other four members of the
initial benchmarking team was to identify which of those many measures were
crucial to the business.
At about the same time as Kodak-Park was launching the internal
benchmarking project, it was beginning to look outside its walls as well. It
found willing benchmarking partners within two professional maintenance
organizations. One, the Plant Engineering Maintenance Managers Conference
(PEMMC), consisted of a group of maintenance managers at eight large
companies who formed a once-a-year networking group.
Step IV: collect data. Collecting the information in the first rounds from all
Kodak's maintenance operations worldwide was not an idle data-gathering
exercise, Berson says. The company used a questionnaire to make sure that
data were being assembled in a uniform manner, a necessity if the numbers
were to have any validity. If a number seemed particularly high or low, a Benchmarking ±
facility manager would be asked to check again. ``Consistency has to be one of best practices
the under-pinning's of a measurement system'', Berson says.
Once the data had been gathered from within Kodak, they was given to a
second team, this one made up of the 36 Kodak managers responsible for
maintenance functions. It was crucial to get them involved in analyzing the
information since they were the ones who had to create individualized 263
improvement plans based on the numbers. ``The whole point behind
benchmarking is understanding where to make the improvement'', Berson
says. ``The number is only the trigger'' (Geber, 1994).
Step V: gap analysis. Once Berson and the team had collected all the numbers,
both internally and externally, they grouped the data into a number of charts
that showed how Kodak-Park stacked up against its benchmarking partners. In
some cases, the verdict was good, in other cases not so good. For instance, the
data confirmed what Berson suspected, and what had prompted the study in the
first place: Kodak-Park did too much reactive, or emergency, maintenance work.
Its reactive work amounted to about 34 percent of the total time spent. That
figure made Kodak-Park roughly equal to the rest of the company, better than
the PEMMC average, but significantly behind the SMRP companies, which
together spent an average of about 19 percent of their time doing reactive work.
On the other hand, Kodak-Park had some of the lowest maintenance costs, as
measured by the category of maintenance cost as a percentage of the cost of the
product.
Step VI: feedback and review. One way to use the information to improve, Berson
says, was to involve the maintenance managers' customers: the manufacturing
heads. Consequently, the benchmarking group devised another survey, this one a
32-question instrument based on the 12 measures Kodak wanted to hack. Each
maintenance manager and the manufacturing manager he served was asked to rate
the performance of the maintenance department. Afterward, the two managers
would sit down to figure out how to improve the maintenance department's
performance. After measuring how it stacked up, and beginning to implement some
of the things it learned from high-performing partners, the Kodak-Park
maintenance unit increased the amount of preventive work by 6 percent in one year.
It made great strides in increasing inventory turnover, saving more than $3
million in the process. Kodak-Park reports that it is on track for more
improvement on turnover that would save an additional $5.5 million by the end
of 1994.
264
Table II.
and Kodak
Comparison of Xerox
Xerox Kodak Comparison
Number of steps in the Xerox has ten steps in its Kodak has only six steps in The number of steps does not signify any deviation
study benchmarking process its benchmarking process from the process of benchmarking. It is simply an
adaptation by the companies to suit their individual
needs, depending on the complexity and size of the
project undertaken. A careful analysis of these steps
shows that they are fundamentally the same as those
proposed earlier in the paper. The number of steps is
adjusted to better enable them to control and monitor
the study
Internal vs. external focus Xerox has an external focus Kodak on the other hand The external vs. internal focus followed by Xerox and
and comparison strategy began by using an internal Kodak is another major difference between the
focus companies. Again the scope of the project may be to
blame for the difference but the problem being studied
also contributes to this. In the case of Xerox, the
manufacturing costs were being studied and Xerox
studied its affiliates and competitors to determine the
benchmark to follow. In the case of Kodak the
comparison was primarily made with Kodak's other
facilities, however, Kodak later started to look at
external sources
Formation of teams The steps followed by However, in the case of Formation of teams in itself is not such a major
Xerox in its benchmarking Kodak, a benchmarking difference but, when teams are formed and given the
process do not explicitly team is established as a authority and responsibility, the study undertaken
depend on the formation of part of the benchmarking becomes a priority. However, looking at the success of
teams to perform the study. process. This team decides Xerox in benchmarking this can be argued
However, teams are formed the problem to be studied
as the study progresses and carries the whole study
to its logical conclusion
(continued)
Process vs. problem based Xerox carried out a process In the case of Kodak, the Recently more emphasis has been place on ``process-
benchmarking orientated benchmarking case seems to indicate a based benchmarking''. So instead of taking one problem
study in the case under more problem-based focus. at a time, the whole process is studied and benchmarked
study. This would imply The management at Kodak against the best in class
that Xerox was in fact tring felt that they had a problem
to benchmark its ``process'' with the maintenance costs
of manufacturing costs and were trying to minimize
rather than a particular itemthe costs. Hence a problem
in the process was identified and a
benchmarking study
undertaken to alleviate it
Formal communication of The benchmarking study at At Kodak no formal means Communicating the findings and results of a
benchmarking findings Xerox incorporates a formal of communicating the benchmarking study makes it easier and brings the
process of communicating findings was apparent importance of benchmarking to the fore. Xerox, being a
its findings to all parts of pioneer, has inculcated the spirit of continuous
the organization, enabling improvement in its organization and that seems to be
the whole organization to apparent from communicating and highlighting the
take advantage of the achievements made by department. This also helps in
results of the new study proposing and identifying possible benchmarking
partners for other studies
Table II.
best practices
265
Benchmarking ±
BIJ As can be seen from Table II, Xerox and Kodak have successfully integrated
6,3 benchmarking into their operating strategies. The benefits derived by both
these organizations are innumerable. In terms of cost savings and customer
satisfaction alone the organizations have saved millions (Worthing Brighton
Press, 1997). At first glance the process looks different as adopted by these
companies, but in fact it is fundamentally the same. Benchmarking has played
266 a significant role in the industry leadership stature of both these organizations.
VI. Conclusion
Camp (1989) calls benchmarking an applied discipline. It cannot be learned by
taking a class or reading a book. It is a hands-on learning experience, and the
drawback to this type of a process is that mistakes are inevitable. However,
senseless mistakes are avoided by setting goals and following the rules to
achieve them. Companies that benchmark identify specific areas of weakness,
and find solutions to turn them into strengths.
Benchmarking is a process that can be and has been adapted to fit the
managerial inclinations of an organization. It can be carried out in 33 steps or just
five, however, the essence remains the same. It is also very important to
remember improvements are continuous and benchmarks go out of date quickly,
the competitor's performance will probably continue to improve in advance of
one's own. The study should always remain honest and thoroughly professional.
During the past several years, through extensive efforts, leading firms have
come to realize that there is a better way to focus benchmarking activities for
greater payback. Formulating a strategy in an attempt to continuously improve
processes has lead to myriad benchmarking steps. This paper attempted to
provide an integrated approach to benchmarking and illustrated the various
methods followed by enumerating the case studies of Xerox and Kodak.
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American Productivity & Quality Center (1997), Using Information Technology to Support
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