80 Metrics to focus EMS provider materials management and increase EMS profits

THE ELECTRONICS MANUFACTURING SERVICES (EMS) business can be a zero-sum game for many EMS providers given many EMS providers often take on new OEM programs at a loss or, in some best case scenarios, with hopes just to break-even until cost-savings can be designed into products and manufacturing efficiencies can start to take hold.

Talk to anyone familiar with the EMS sector and they’ll tell you the materials cost of goods sold (MCOGs) in most EMS business models can run between 75% to 80% (or more).

With this point in mind, one can see how any EMS provider wanting to be profitable must focus management efforts on managing materials and the materials controls aspect of his business (purchasing, planning, scheduling, inventory control…).

This can be a daunting challenge considering the EMS industry norm for ‘scrap’ for an EMS model should be kept below 1%.

The following are 80 key metrics EMS provider materials managers should focus on when responsible for what many consider to be the lion’s share of an EMS model’s opportunities for profit.

Metrics managed internal the EMS provider can be done so and presented / updated daily; weekly, monthly, quarterly… or to whatever frequency helps EMS providers maintain focus to meet their EMS (and let’s not forget OEM customer) business objectives. (Metrics listed are not presented in order of importance)

80 Key metrics EMS providers must focus on to improve materials management and increase EMS profits

1. Master production scheduling: Number (#) of master production scheduler (MPS) changes within next 4 weeks
2. # of MPS changes within 5-8 weeks out
3. # of MPS changes within 9-13 weeks out
4. % performance to [insert your company name here] commit
5. Units forecast / requested
6. % performance to [insert your company name here] loading / OEM customer request
7. # of EDI lines not correct
8. Monthly MPS / COGS Report
9. Purchasing: # Part numbers (See, also: Sourcing/planning drives materials)
10. # Part numbers added during period
11. # Part numbers deleted during period
12. # Purchase order (PO) numbers placed
13. # Purchase order (PO) lines new
14. # Purchase order (PO) lines changed
15. # Purchase order (PO) lines canceled
16. # Part numbers on pull programs
17. # Part numbers on regular order programs
18. On time delivery percentage (% early, % on time, % late)
19. $ Purchase price variance (PPV)
20. $ Value NPV recovered from customer
21. $ Value PO receipts planned for next month
22. Track # various key part numbers, whether from OEM, EMS provider, per distributor
23. # Purchase order lines past due
24. # Requisition lines open
25. Planning: # Printed circuit board assembly (PCBA) shortages in 1 week window for EMS provider
26. # Printed circuit board assembly (PCBA) shortages in 1 week window OEM
27. # Printed circuit board assembly (PCBA) shortages in 1 week window per distributor(s)
28. # Box build shortages in 1 week window EMS provider
29. # Box build shortages in 1 week window OEM
30. # Printed circuit board assembly (PCBA) line / hours downtime due to shortages by EMS provider
31. # Printed circuit board assembly (PCBA) line / hours downtime due to shortages by OEM
32. # Printed circuit board assembly (PCBA) line / hours downtime due to shortages by distributor(s)
33. # Box build assembly line / hours downtime due to shortages by EMS provider
34. # Box build assembly line / hours downtime due to shortages from OEM
35. Inventory turns this month
36. Inventory turns projected next month
37. $ Inventory value in [system] this month
38. $ Inventory value projected in [system] (i.e., ERP systems) next month
39. $ Inventory value per [system] this week
40. $ Exposure zero demand (No MPS / No bill of materials (BOM))
41. $ Exposure inactive surplus (No MPS / Yes BOM)
42. $ Exposure active surplus (Yes MPS / Yes BOM)
43. # A, B, and C part numbers (purchased) (based on $ value per part segment where $ value for A > B > C…)
44. Warehouse: # Line items received in [system]
45. # Line items challenged in [system]
46. # Line items issued in [system]
47. # Line items returned [system]
48. # Line items into [system] materials review board (MRB)
49. $ Into [system] MRB
50. $ Out of [system] MRB
51. $ MRB in [system]
52. $ All Inventory in [system]
53. Square footage warehouse(s)
54. $ Inventory value in [system] per stockroom / area(s)
55. $ Inventory value in [system] in repair / MRB area(s)
56. $ Inventory value in [system] related to cycle count challenges
57. $ Inventory value in [system] for PCBA work-in-progress (WIP) area(s)
58. $ Inventory value in [system] for box build assembly WIP area(s)
59. $ Inventory value in [system] for PCBA test areas
60. $ Inventory value in [system] for untested printed circuit boards
61. $ Inventory value in [system] for main stock area(s)
62. $ Inventory value in [system] per receiving inspection area(s)
63. $ Inventory value in [system] per various distributor warehouse
64. $ Total Inventory value in [system] per EMS provider location / region
65. # Hourly paid employees graveyard shift
66. # Hourly paid employees day shift
67. # Hourly paid employees swing shift
68. # Hourly paid employees in inventory control
69. # Hourly paid employees MRB
70. Inventory control: # Cycle count requests for [system]
71. # System cycle counts
72. $ Scrapped in [system]
73. $ Positive-adjusted cycle counts in [system]
74. $ Negative-adjusted cycle counts in [system]
75. Cycle count accuracy by location(s) in [system]
76. Shipping imports / exports: # Shipments made to various location(s) (USA, Europe, intra-company…)
77. # Shipments received from various location(s)
78. Quotes: # Part numbers quoted
79. Engineering change orders (ECO): # ECO received
80. # BOM lines affected

There are at least two or three dozen more metrics not listed above. Know something not on the list? Are some metrics missing you feel should be included? Share your thoughts below.