manufacturer peer pulse: preparing for reopening · • uncertainty of covid-19 spread, slumping...
TRANSCRIPT
MANUFACTURER PEER PULSE
Preparing for Reopening and Workforce Reentry Under COVID-19
May 1, 2020
1
REOPENING SOON
2
What is your best estimate for the earliest date by which all of your company’s U.S. facilities will be fully reopened or restored to new “normal” operations?
9%12%
28%
20%
5% 5%
1% 1%
5%
1%
13%
Alreadyfully
operational
May June July August September October December 1H 2021 Untilvaccine isavailable
Too hard tosay
n=75 MAPI member executives who completed an online survey, April 23-28
CONTENTS
Current Conditions
Assessing Readiness
Prioritizing Safety
3
• Operational status and capacity utilization
• Management challenges
• Supplier and customer stability
• Milestones and approvals
• Plan input and decisions
• Plan documentation
• Executive confidence
• New work arrangements
• Emerging safety policies and practices
• Asia-Pacific insight
KEY TAKEAWAYS
• High confidence to fully reopen – respondents report confidence in preparedness to execute effectively on
critical return to work policies under COVID-19, including: screening, use of facial coverings and PPE, social
distancing, cleaning and disinfecting, workforce safety communications, telework, and travel restrictions.• Coronavirus testing requirements is a critical exception in preparedness.
• Uncertainty of COVID-19 spread, slumping demand, and workforce safety top management challenges.• Capacity utilization is lower for 9 in 10 companies during the pandemic, and over half of executives report moderate to
extreme change in number of factory employees working regular hours right now.
• Industry consensus is emerging on must-have safety practices at facilities – 89% are requiring 6 feet of
distance between employees, and more than two-thirds are banning outside visitors except for deliveries.• New work arrangements include reinstating employees in stages, rotating teams, staggering start times, and
customizing hours and shifts, among other creative solutions.
• Policy setting is mostly centralized but implementation varies by facility – about 90% of companies
report documenting screening protocols, for example, and the standards differ by facility for 46% of them.
• Government guidance, demand levels, and other metrics are key indicators to proceed – 74% of
approvals for return to work will require CEO sign off with a longer tail of internal and external stakeholders. • Return to work in the Asia-Pacific region offers important lessons on key protocols, leadership, and government roles.
4
Current Conditions
Assessing Readiness
Prioritizing Safety
5
• Operational status and capacity utilization
• Management challenges
• Supplier and customer stability
LARGE DROPS IN CAPACITY UTILIZATION
6
What percentage of your U.S. locations are either
partially or completely shut down? (i.e., a majority of
workers are not working in-person at company buildings
due to company policy and/or local restrictions)
Overall, which of the following best describes the change to your company’s U.S. operations from levels prior to the COVID-19 pandemic? (e.g., due to closures or decreased demand)
n=75 MAPI member companies
42%
23%
28%
8%
12%
1%
8%
4%
10%
35%
29%
Factories Corporate offices
All76% - 99%51%-75%25% - 50%< 25%None
n=75
7%
31%
11%
15%
20%
31%
31%
43%
35%
23%
29%
19%
29%
9%
23%
21%
9%
6%
6%
2%
Capacity utilization
Percentage of factories that areoperational
Number of factory employeeswho are working regular hours
Average weekly hours of factoryemployees who are working
No change Low Moderate High Extreme
44%
39%
37%
33%
28%
27%
19%
19%
19%
9%
3%
1%
1%
8%
Uncertainty of COVID-19 spread (e.g., second wave)
Financial stability of end customers
Employee willingness to return to work (e.g., safety concerns)
Ability to source PPE and other medical supplies (e.g., masks, thermometers)
Employee ability to return to work (e.g., illness, child care, public transportation)
Supplier capacity (e.g., disruption, financial instability)
Coordination of workforce reentry (e.g., cadence and phases)
Compliance with all local and federal regulations
Ability to source materials to run facilities and offices (e.g., hand sanitizer, paper products)
Implementations of employee safety standards (e.g., screening)
Consistency in internal guidelines across regions and localities
Union concerns
Leadership consensus on policy or procedures for reopening
Other
COVID-19
CHALLENGES: COVID SPREAD, ECONOMY, SAFETY
7
What are your company’s top three challenges to reopening or fully restoring operations?
n=75
• Changing the mindset of
leadership and employees long
term about the new normal and
prolonged, rigorous adoption of
safety protocols
• Screening and testing both
antigen and antibody
• Customer demand
• Efficiently running plant at low
utilization rates = bigger losses
• The lack of general population's
understanding of face covering
recommended use
Demand or Supply
Workforce
MANAGING SUPPLIER UNCERTAINTY
8
Is your company providing assurance to suppliers
about the status of your company’s workforce and
operations?
Is your company requiring assurance from customers
about the status of their company’s workforce and
operations?
41%
21%
11%
3%
24%
Providing when requested
Providing voluntarily
No plans to provide information
Considering
Unsure
n=75
13%
40%
12%
35%
Requiring it
No plans to make this arequirement
Considering a requirement
Unsure
n=75
Current Conditions
Assessing Readiness
Prioritizing Workforce
Safety
9
• Milestones and approvals
• Plan Input and decisions
• Plan documentation
• Executive confidence
KEY INDICATORS: AUTHORITIES, METRICS, DEMAND
10
Which of the following metrics or milestones is your company using to determine timing of reopening or
fully restoring U.S. operations?
91%
43%
39%
33%
25%
11%
11%
5%
Federal, state, and local regulations and guidance
Downward trajectory of documented cases within a 14-dayperiod
Level of demand for products
State and/or local Chamber of Commerce guidance
Implementation of policies and procedures for workforcecontact tracing following a positive employee COVID test
Percentage of employees tested for COVID-19
Percentage of employees able to return to work
Other
n=75
• Institute for Health Metrics and
Evaluation (IHME) analysis by state
• Ability of people to work effectively/
productively remotely versus in the
office environment; availability of
treatments, vaccines, and/or sufficient
testing to reduce exposure risks
DIVERSE APPROVALS REQUIRED
11
Whose approval is required for reopening or fully restoring operations at your company’s facilities?
74%
56%
41%
32%
26%
23%
23%
14%
8%
8%
5%
4%
1%
1%
1%
18%
CEO
Crisis management team
Chief Human Resources Officer
General Counsel or Chief Legal Officer
Plant manager
Head of EHS
CFO
Head of Safety
Head of Risk
Centers for Disease Control and Prevention (CDC)
Public Health Department
Occupational Safety and Health Administration (OSHA)
Factory Investigation Commissions
Union representatives
Head of Internal Audit
Other
n=75
• Head of Operations / COO
• Division Presidents
• Our Executive Leadership Team
together
• Collaboration of business units and
location leadership with Corporate
Executive Council
• Supply Chain and Manufacturing VPs
• Corporate Medical Advisor
EXTENSIVE INPUT INTO COMPANY PLANS
12
Which of the following sources is your company using for input into plans to reopen or restore
operations at its facilities?
96%
88%
83%
55%
49%
41%
40%
31%
24%
19%
17%
11%
9%
4%
State and local governments
Centers for Disease Control and Prevention (CDC)
Federal government
Existing internal plans (e.g., protocols for crisis management)
Occupational Safety and Health Administration (OSHA)
Local Health Department
Regional leadership at your company
Outside legal counsel
State and local Chamber of Commerce
Equal Employment Opportunity Commission (EEOC)
Outside infectious disease doctors/specialists on retainer
Unions
Currently under consideration
Other
n=75
Institute for Health Metrics and
Evaluation (IHME) analysis
MOSTLY CENTRALIZED POLICY SETTING
13
For each of the following areas please indicate where decisions on specific policies or procedures are
primarily made?
n=75
21%
23%
31%
33%
36%
36%
52%
77%
40%
39%
43%
36%
24%
37%
28%
15%
36%
32%
24%
27%
13%
24%
17%
4%
3%
7%
3%
4%
4%
3%
1%
1%
23%
1%
3%
Use of personal protective equipmentand face coverings
Cleaning and disinfecting protocols
Safety communications to employees
Screening protocols (e.g., temperaturechecks)
Testing requirements for COVID-19
Social distancing
Telework policy
Business travel restrictions At corporate (i.e.,centrally managed)
Mostly corporate,with some local input
Mostly local withsome corporate input
Locally, by facility(e.g., plant leadershipand authorities)
Not applicable
SOME DOCUMENTED STANDARDS VARY LOCALLY
14
To what extent has your company formalized each of the following policies or procedures for
facilities in the U.S.?
n=74
32%
43%
55%
64%
64%
72%
77%
96%
11%
46%
41%
36%
26%
28%
22%
3%
42%
8%
4%
9%
1%
1%
15%
3%
1%
Testing requirements for COVID-19
Screening protocols (e.g., temperaturechecks)
Use of personal protective equipment andface coverings
Cleaning and disinfecting protocols
Telework policy
Safety communications to employees
Social distancing
Business travel restrictions
Documented anduniform by facility
Documented butvaries by facility
Not formalizedcurrently
Not applicable
3%7%25%
4%
3%2%4%9%
13%
21%
19%31%
28%39%48%44%
41%
25% 81%69%66%59%
48%47%39%
25%
Business travelrestrictions
Safetycommunications
to employees
Telework policyCleaning anddisinfectingprotocols
Use of personalprotective
equipment andface coverings
Social distancingScreeningprotocols (e.g.,temperature
checks)
Testingrequirements for
COVID-19
Not applicable Not at all confident Not very confident Confident Very confident
LOWEST CONFIDENCE IN COVID TESTING
15
With current policies and resourcing in place at your company right now, how confident are you that all of
your company’s U.S. facilities are prepared to execute effectively on the following upon reopening?
n=75
Current Conditions
Assessing Readiness
Prioritizing Workforce
Safety
16
• New work arrangements
• Emerging safety policies and practices
• Asia-Pacific insight
61%
46%
37%
34%
30%
25%
22%
19%
14%
10%
34%
41%
37%
31%
34%
52%
42%
48%
52%
25%
4%
10%
21%
28%
22%
17%
30%
30%
28%
55%
1%
3%
5%
7%
14%
6%
6%
3%
6%
10%
Telecommute (part-time remote work)
Stagger start times
Reinstate activities by role or by type of work
Reinstate by function
Reopen by region
Rotate team (e.g., diving function in half)
Alternate days between shifts
Condense workweeks (e.g., 4-day work week)
Customize working hours (e.g., parents start work later)
Shorten schedules (e.g., leave 2 hours earlier)
Implementing Considering Not considering NA
PHASING IN NEW WORK ARRANGEMENTS
17
What work arrangements is your company implementing or considering for the first phase of
reopening or restoring operations at any of your U.S. locations?
n=69
EMERGING SAFETY POLICY ESSENTIALS
18
Which of the following general policies will your company have in place for employee safety at a
majority of U.S. facilities?
97%
89%
69%
65%
64%
51%
49%
13%
9%
15%
Cleaning and disinfecting protocols
At least 6 feet of distance between employees at all times
Bans on outside visitors except delivery services
Masks or face coverings required at all times in company buildings
Signs or floor markings to indicate barriers between employees
Common spaces closed (e.g., cafeteria, break room)
Physical barriers between employees
Tracking of employees throughout premises
Gloves required at all times in company buildings
Other
n=75
• Mandatory temperature checks
• Medical screenings
• We are still determining our mask
policy and visitor policies
• Closing smaller conference rooms
88%
67%
61%
59%
28%
22%
17%
7%
4%
6%
New/heightened hygiene requirements
New/heightened PPE requirements
Regular health screenings for all employees (e.g., temperature checks)
Requirement for use of facial coverings or medical facemasks on premises
Health screening for all employees in a facility after a positive test
Fitness for duty form from doctor
COVID-19 testing requirements
Medical staff on premises
Antibody testing requirements
Other
NEW MEDICAL PRACTICES AND PRECAUTIONS
19
Which of the following medical practices will your company have in place for employee safety at a
majority of U.S. facilities upon reopening?
• Testing requirements and
abilities to actually test are
still undetermined
• Common sense and
training
n=69
GLOBAL INSIGHT: ASIA-PACIFIC EXPERIENCE
20
Which countries/regions in which your company
operates is furthest in returning to a “normal” level
operations after partially or completely shutting down?
For the country or region specified, what has been the
most important factor in safely and successfully restoring
operations to a new “normal” level?
Protocols
• Strong emergency management team with established
communication and operating protocols
• Implementing a number of safety protocols such as
temperature checks, social distancing, including providing
company busing versus public transportation, focusing on
hygiene, etc.
• Stringent safety protocols in compliance with Chinese
government
• Testing where available (esp. China) and comprehensive
protocols for protecting employees
• Face masks, social distancing, temperature checking,
enhanced cleaning protocols
• PPE, temp screening, social distancing engineering controls,
such as plexiglass barriers
• Testing; confirmation of locations visited; travel bans
• Testing, social distancing and cleanliness standards
• Cleaning, testing, and PPE
61%
19%
12%
4%
1%
3%
Asia Pacific
We did not have closures
Our global operations are stillpartially or completely shut down
Europe
Mexico
We do not operate outside of theU.S.
n=74
21
VERBATIM: GLOBAL SUCCESS FACTORS (CONTINUED)Protocols (continued)
• PPE and social distancing
• Following guidelines of social distancing and wearing masks
• Formalized medical screening through an online questionnaire combined with some level of antigen/antibody testing
• Availability of PPE for employees; lower number of cases being reported
• Downward curve in new COVID-19 positive cases
Leadership communication and preparedness
• Very structured, well documented processes (program for all elements of employee return, entry, in place work requirements,
PPE, testing, quarantine, etc.)
• Experience in dealing with similar pandemic situations in the past
• Good employees, with careful distancing and especially keeping sick folks home for work
• Communication from our CEO, social distancing, and flexible schedules
• Pandemic health and safety precautions in place; regional state and local alignment to be considered essential to operate;
reasonable supply and demand to justify running
• Ensuring supply chain stability
Local government
• Government restrictions/guidelines
• China government control = reduction in infections
• This relates to China: reducing infection rates, ending lockdowns, and reopening of OEM customers
• The country metrics showing major decline in positive test results
• Government agreement and proper PPE and cleaning provisions
< $500M5%
$500M to $999M 17%
$1B to $2.9B31%
$3B to $4.9B 23%
$5B to $9.9B12%
$10B or >12%
16%
15%
14%
14%
11%
Miscellaneous manufacturing
Electrical equipment, appliance,and component manufacturing
Transportation equipmentmanufacturing
Machinery manufacturing
Fabricated metalproduct manufacturing
22
ABOUT THE SURVEY
Annual Revenue of Company
Industries Represented (Top-5)MAPI Member Executive Participation
n=75 companies
28%
20%
15%
9%
7%
5%
4%
4%
8%
EHS
Human Resources
Manufacturing
Risk Management
Law
Ethics and Compliance
Division Leadership
Engineering and R&D
Other