Automotive Industry

Top 15 Automotive KPIs to Measure for Operations Executives

October 31, 2023

In the fast-paced world of automotive manufacturing, Operations Executives play a pivotal role in ensuring operational efficiency, meeting customer demands, and staying competitive. They use Key Performance Indicators (KPIs) to gain insight into vital business areas that will help them succeed in this competitive environment. This article will discuss the top 15 Automotive KPIs for Operations Executives, broken down into several groups for different areas of car production.

The Role of Key Performance Indicators in Automotive Operations 

 These indicators are essential for improving productivity, cutting expenses, and maximizing efficiency. Each automotive industry KPI plays an important role in guaranteeing the competitiveness and success of automotive manufacturing operations, from measuring equipment efficiency to monitoring on-time deliveries, regulating costs, and enhancing personnel productivity. 

High product quality and stable supply chains can also be maintained using automotive KPIs for quality control, sustainability, and supplier performance. In this fast-paced, highly competitive business, Operations Executives can use these KPIs to make data-driven choices, streamline processes, and ultimately lead their firms to excellence.

Production Efficiency KPIs

Overall Equipment Effectiveness (OEE)

OEE quantifies the percentage of anticipated production time that is genuinely productive. There is much room for growth, as many production lines barely operate at 60% efficiency.

Measures the efficiency of production machinery by looking at its accessibility, productivity, and output quality. By keeping an eye on OEE, Operations Executives may improve production efficiency, cut down on unplanned downtime, and raise the bar for product quality.

Formula: OEE = Availability x Performance x Quality

Cycle Time

When OEE is high, production expenses can be cut by 25%, and output can be increased by 40%. A 20% decrease in cycle time can result in a 33% increase in production capacity.

A manufacturing process’s cycle time is the total time it takes to go from the beginning of the process to the end. Keeping an eye on cycle time is a great way to streamline operations and ensure timely product delivery.

Formula: Cycle Time = Total Processing Time / Number of Units Produced

Inventory Turnover

The inventory turnover rate measures how rapidly a business sells through its stock and restocks its shelves during a specified time frame. A high inventory turnover ratio indicates efficient stock management, decreased expenses, and increased profits.

Formula: Inventory Turnover = Cost of Goods Sold (COGS) / Average Inventory Value

Quality Control KPIs

Scrap and Rework Rates

Reducing scrap rates by 10% can result in a 5% increase in overall equipment efficiency. High scrap rates can cost manufacturers up to 15% of their revenue.

The rate at which useable goods are discarded during production is known as the scrap rate. Reducing the amount of waste created during production can save money and improve the quality of the final product.

Formula: Scrap Rate = (Number of Defective Units / Total Units Produced) x 100%

Supply Chain and Delivery KPIs

On-time Delivery

On-time delivery is a critical factor in customer satisfaction, with 96% of customers expecting their orders to arrive on time. Failing to meet delivery expectations can lead to a customer churn rate of up to 25%.

The percentage of orders fulfilled by the estimated delivery date is the metric used to determine on-time delivery. Maintaining a competitive edge and pleasing customers, both depend on reliably meeting delivery deadlines.

Formula: On-time Delivery Rate = (Number of Orders Delivered on Time / Total Number of Orders) x 100%

Cost Management KPIs

Cost Per Unit

Optimizing cost per unit can lead to a 10% increase in profitability. Understanding and controlling cost per unit is key to maintaining a competitive edge in the automotive industry.

A product’s “cost per unit” measures how much it costs to make one item. Cost-per-unit analysis is useful for analyzing profit margins, developing pricing strategies, and controlling costs.

Formula: Cost Per Unit = Total Production Cost / Number of Units Produced

Employee Productivity KPIs

Employee Productivity

Gallup found that companies with engaged employees had 21% higher productivity and 28% lower instances of employee theft than those with disengaged employees. Employees who are invested in their work are creative and always have a few suggestions for how things may be done better.

Worker productivity is the amount of work accomplished by a group of people during a given time frame. Boosting productivity in the workplace has a multiplier effect on business success.

Formula: Employee Productivity = (Total Output / Number of Employees)

Customer Satisfaction KPIs

Warranty Claims Rate

A 5% increase in customer retention can boost profits by 25% to 95%. Reducing the warranty claims rate can significantly improve customer satisfaction and brand reputation.

The percentage of products that need to be serviced or repaired falls under the purview of the warranty claims rate. Decreases in the number of warranty claims received indicate product and customer satisfaction.

Formula: Warranty Claims Rate = (Number of Warranty Claims / Total Units Sold) x 100%

Environmental Sustainability KPIs

Sustainability Metrics

Automotive companies KPI with strong sustainability programs can see a 5.2% increase in stock price. Monitoring and improving sustainability automotive metrics align with modern consumer preferences and regulatory requirements.

These automotive KPIs for sustainability include those measuring things like energy use, water use, and greenhouse gas emissions. Sustainable practices are becoming more of a priority for the auto industry to satisfy government mandates and customer expectations.

Lean Manufacturing KPIs

Downtime Percentage

Reducing downtime by 10% can lead to a 5% increase in manufacturing capacity. Minimizing downtime is essential for just-in-time manufacturing and resource efficiency.

The proportion of downtime for manufacturing equipment is a measure of its inefficiency. Reduced downtime increases output, lowers manufacturing costs, and guarantees effective use of available resources.

Formula: Downtime Percentage = (Total Downtime / Total Production Time) x 100%

Supplier Performance KPIs

Supplier Performance

Poor supplier performance can lead to product recalls, affecting reputation and revenue. Effective supplier performance management is vital for maintaining a seamless supply chain.

Automotive KPIs for suppliers evaluate how consistently reliable, high-quality, and on-time deliveries are. Supply chain continuity relies on constant monitoring of supplier performance.

Formula: Supplier Performance = (Number of Deliveries On-time and In-full / Total Number of Deliveries) x 100%

Operational Cost KPIs

Labor Cost as a Percentage of Sales

Labor costs can account for up to 65% of total production costs. Monitoring labor costs is crucial for optimizing workforce management and overall cost control.

Spending on labor as a proportion of sales is measured by this key performance indicator. Labor cost monitoring contributes to better human resource management and overall budget management.

Formula: Labor Cost Percentage = (Labor Cost / Total Sales) x 100%

Safety and Compliance KPIs

Incident Rate

The automotive industry average ratios of 26% reduced workers’ compensation expenses in the four years following a Cal/OSHA inspection, and injury claims dropped by 9.4% compared to a similar group of uninspected workplaces. Over that time period, the typical inspected company saved $355,000 in worker compensation costs and injury claims. 

The number of accidents or other safety occurrences per time unit can be calculated using the incident rate. Maintaining a low incident rate is essential for worker protection and legal standing.

Formula: Incident Rate = (Number of Incidents / Total Work Hours) x 1000 (usually per 1000 work hours)

Machine Utilization KPI

Increasing machine utilization can lead to a 10% reduction in production costs. Optimizing machine utilization enhances production efficiency and reduces costs.

This automotive sector KPI measures manufacturing machine utilization. Maximizing machinery use increases output while decreasing overhead.

Formula: Machine Utilization Rate = (Actual Machine Operating Time / Total Available Machine Time) x 100%

Material Waste KPI

Reducing material waste by 10% can result in a 10% reduction in material costs. Minimizing material waste is both cost-effective and environmentally responsible.

The percentage of raw materials lost during production is the material waste percentage. Minimizing material waste has financial and environmental benefits.

Formula: Material Waste Percentage = (Total Material Waste / Total Material Used) x 100%

These 15 Automotive KPIs are extremely useful for Operations Executives in the ever-changing automotive industry. They may improve their company’s performance in the cutthroat automotive sector by measuring and evaluating these variables thoroughly, allowing them to make data-driven decisions and increase operational efficiency.

How do Automotive Companies Track their KPIs?

When it comes to KPIs, the automobile industry relies on both industry-specific ERP software and more generic automotive manufacturing KPI software systems. These platforms give users access to real-time data that may be used to track automotive KPIs, measure performance, pinpoint problem areas, and more.

You may get the same basic picture of performance by combining other tools, such as spreadsheets, native programs, and manual tracking.

In the fast-paced automotive business, having this data readily available on an automated KPI Dashboard or report is crucial for making choices and taking action.

How can Brickclay Help?

Executives in the automobile industry have a challenging environment to maintain productivity, quality, and success. This blog’s discussion of the top 15 automotive KPIs offers a comprehensive analysis of the sector. Operations Executives acquire essential insights to make data-driven decisions by rigorously measuring indicators relating to production efficiency, quality control, supply chain management, cost control, staff productivity, sustainability, and more. 

These metrics allow for on-time delivery, cost management, waste prevention, and improved product quality. In addition, they facilitate preventative approaches to sustainability, safety, and regulatory compliance. These measures are vital for the ever-changing automotive industry to preserve competitiveness and encourage new ideas. These automotive KPIs are as relevant as ever, helping Operations Executives succeed in an increasingly complex and competitive market. 

Brickclay is well-equipped to help car companies on this path because of its data engineering knowledge. Contact us if you’re in the automotive industry and want to discuss how we can help you improve operations and grow your business.

About Brickclay

Brickclay is a digital solutions provider that empowers businesses with data-driven strategies and innovative solutions. Our team of experts specializes in digital marketing, web design and development, big data and BI. We work with businesses of all sizes and industries to deliver customized, comprehensive solutions that help them achieve their goals.

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