Production planning and control tools

There are numerous tools available to be used for production planning and control purposes. The number of tools is ever increasing, and so are the levels of sophistication as well as complexity. For the specific manufacturing firm, the task of selecting the most appropriate set of tools is not trivial. However, in recent years, the understanding of the relationship between tools and manufacturing environments for which they are suitable has increased. The purpose of this paper is to provide an overview of production planning and control tools available today, as well as new trends, issues and ideas.     

The integration of TQM and technology/R&D management in determining quality and innovation performance

This paper presents an empirical study which examines the co-alignment between Total Quality Management (TQM) and technology/research and development (R&D) management in predicting organizational performance in terms of quality and innovation. This study improves our understanding of the relationship between TQM and innovation based on the following two major issues. First, this study contributes to the understanding of the co-alignment between TQM and technology management along with R&D management by bridging the gap between the two areas which are often addressed in a separate fashion. Second, this study also examines the impact of the integration between TQM and technology/R&D on quality and innovation performance which have been considered as the primary sources of a competitive advantage. The empirical data was drawn from 194 Australian organizations and analyzed using the Structural Equation Modeling (SEM) technique. The findings indicate that TQM shows a strong predictive power against quality performance but no significant relationship against innovation performance. On the other hand, technology and R&D management shows a significant relationship with quality performance but at a lower level than that of TQM, and shows much stronger relationship with innovation performance. In addition, there is strong and positive correlation between TQM and technology/R&D management. The major implication of this study is that technology/R&D management is an appropriate resource to be used in harmony with TQM to enhance organizational performance, particularly innovation.     

Employee strain and job satisfaction related to an implementation of quality in a public service organization: A longitudinal study

To date, few studies have focused on employee reactions to the quality-related aspects of the introduction of New Public Management (NPM). The aim of this study was to investigate the effects on employee strain and satisfaction of the implementation NPM in a public service organization. The study was designed as an empirical examination of the 'context-dependent approach' ( Edwards, Collinson, & Rees, 1998 ). This approach suggests that effects of an organizational change depend on the context of the implementation, i.e. organizational aspects (implementation strategies), job content and job context dimensions. They employed a single-case longitudinal design. The case was a large municipal service unit responsible for the public housing system of a city in Austria. The sample consisted of 217 employees. Measurements were taken before the organizational change, and at two different times during the change process. While the implementation of NPM can be considered to have been an organizational success (increase in customer satisfaction), it was accompanied by increases in job strain, and, at the same time, mixed results in job satisfaction. Less qualified employees mainly responsible for the customer interface experienced the organizational change most negatively. Using structural equation modelling, the context-dependent approach was empirically confirmed. Job control, role clarity and information were found to be the most important job and organizational resources.     

A note on an economic production quantity model and just-in-time production

In this paper an economic production quantity (EPQ) model in which the production rate is variable is studied. An analysis is presented of the impact of a variable production rate on the optimal production quantity and the total relevant cost. It is observed that this EPQ production and inventory system, in which the production rate is close to the demand rate, possesses many characteristics that are similar to a just-in-time (JIT) production system. It is shown that the normal prerequisites and benefits of JIT production can be identified from an analysis of such an EPQ system.     

An investigation into the use of OPT production scheduling

The paper is a case study describing the experience of a single company which uses OPT software for production scheduling. The company produces a range of over 500 different items. Optimized Production Technology (OPT) is a proprietary computer software. Although the OPT software requires a similar database to MRP systems and addresses the same problems, OPT is a finite scheduler, unlike MRP which assumes (unrealistically) infinite capacity. The paper defines the underlying terminology and explains the major features of the algorithm underpinning the software. Details of the scheduling frequency, scheduling routine and reports are described. Practical implications observed are the necessity of short process routes and a multi-skilled workforce (somewhat like the case of JIT cells). Benefits of using the system are discussed.     

The dual effect of board gender diversity on R&D investments

We examine how gender diversity on boards of directors affects investment in research and development (R&D), thereby providing the platform for future ambidexterity of the organization. Using quantitative data from 44 countries, that are exemplified by qualitative data, our findings show that gender diverse boards result in more complex organizational outcomes in regard to R&D investment than assumed originally. Our findings show that gender diverse boards encourage ambidexterity. On the one hand, increased gender diversity has a negative direct effect on R&D. However by positively affecting equity based remuneration, these diversified boards actually encourage indirectly higher R&D investments that are better correlated with the organization goals. Gender diversity on boards, therefore, encourages organizational behavior that increases the chances for higher ambidexterity over time by encouraging exploitative behavior as well as explorative behavior.     

‘Management Standards’ and work-related stress in the UK: policy background and science

In the late 1990s, the Health and Safety Commission, as the lead authority in the UK responsible for Health and Safety at Work, conducted an extensive consultation exercise to elicit views about how work-related stress should be tackled. The Commission subsequently decided that regulation was not justified and opted for an approach with four strands. One of these was to work with stakeholders to develop clear, agreed standards of good management practice. This paper describes and discusses the rationale behind a standards-based approach that is essentially based on a method of controlling hazards. The Management Standards approach uses a taxonomy of six stressors that has evolved out of extensive research carried out on behalf of the UK's Health and Safety Executive (HSE) and in conjunction with stakeholders, and a three-phase risk assessment methodology. Further developmental work on the standards (which are to be subjected to public consultation) and associated measurement tools is described in a companion paper in this issue of Work & Stress (Cousins, Mackay, Clarke, Kelly, Kelly, & McCaig, ). The emphasis is on prevention towards reducing stress in the UK working population. We review current thinking on models of work stress, consider evidence linking workplace psychosocial factors and various health and organizational outcomes, and examine the effectiveness of organizational interventions. We argue that the literature supports an approach that aims to move organizational states (represented by the current situation) to more desirable ones (represented by the six Management Standards), and that this is an effective ‘population’ based approach to tackling workplace stress and promoting individual and organizational health.     

Total production control

The new requirements for enterprise flexibility, quality improvement, costs and throughput limes reduction cannot be achieved by using traditional approaches. While US and European industry developed the grand CIM, FMS, CAD/CAM and MRP II projects, Japan introduced just-in-time and lean production, not to demonstrate the possibilities of the new technology but to expose operational inefficiencies and waste in the manufacturing process. The main CIM effort was in the flexibility and productivity improvement, bin its implementation stressed above all the technical aspects of the factory integration and the most flexible production factor, people, remained in the background. The new technology must be implemented into the organizational framework that uses and develops the skills, knowledge and creativity of the human resources. People in the production process need a new kind of decision support in the rapidly changing business environment. A new concept, total production control (TPC), that is a reaction to the present manufacturing problems will be presented. TPC integrates many methods and tools for production system analysis and improvement, production system design and production planning and control. This concept emphasizes a preventive aspect of the problem solution in the production process and supports a production manager at the three time views: past (archive and statistical database); present (shopfloor data capture and production progress monitoring); and future (simulation and modelling tools).     

Business intelligence and analytics value creation in Industry 4.0: a multiple case study in manufacturing medium enterprises

Abstract

Medium enterprises (MEs) form a majority of enterprises in several regions, yet they are underrepresented in the literature. The digital transformation known as Industry 4.0 (I4.0) brings new data streams into enterprises. MEs and large enterprises will both leverage business intelligence and analytics (BI&A) to improve their business performance, so the study of the conditions favouring value creation of BI&A is of interest. However, there are few studies focusing on the impact of business intelligence and analytics (BI&A) on value creation in I4.0 and none focusing on MEs. Using a multiple case-study design, this paper explores factors linked to BI&A business value creation in manufacturing MEs that are undergoing an I4.0 transformation. Findings suggest enterprises resources and capabilities are not sufficient to predict business value: organizational learning and organizational culture have a non-negligible influence for MEs.     

A diagnostic analysis of the impact of forecast errors on production planning via MRP system nervousness

Abstract. The purpose of this paper is to examine the impact of forecast errors on the performance of a multi-product, multilevel production planning system via MRP system nervousness. The accuracy of forecasting methods was at one time a major concern of production scheduling and inventory control. However, with the advent of material requirements planning (MRP) systems, the significance of selecting an accurate forecasting method has diminished. Inaccurate forecast results are taken as a fact of life in production planning. Instead of attempting to develop an accurate forecasting method, efforts have been devoted towards providing an appropriate buffering method ai the master production schedule level or on the shop floor level to counteract fluctuations in demand. MRP is capable of rescheduling planned orders as well as open orders to restore the priority integrity after the disruptive changes of forecast errors occur. Nevertheless, excessive rescheduling may lead to a problem, generally referred to as system nervousness. This study investigates this problem by means of a computer simulation model. The results show that the presence of forecasi     

Organizational Slack and Corporate Greening: Broadening the Debate

Organizational slack seems to have an ambiguous relationship with corporate greening. On the one hand, excess resources can be used to experiment with new environmental innovations, or potential green market segments. On the other, excess resources can be used to build corporate buffers against pressures for environmental improvement, such as large corporate environmental departments or environmental lobbying activity, and resist changes to the core of the organization. This paper begins to resolve these conflicting arguments by broadening the debate on organizational slack and corporate greening. It builds on recent empirical studies of slack and corporate greening, and recognizes the many potential roles that different types of slack may play in a dynamic decision–making context. Using a theoretical framework suggested by Bourgeois (1981), the paper systematizes and draws lessons from examples of the roles of slack encountered in a recent series of 35 interviews within UK public limited companies. It concludes that future treatments of slack and environmental management should incorporate a more holistic view of slack, which recognizes its dynamic, complex and often contradictory effects on decision–making in organizations.     

Comparisons of Performance and Job Insecurity in Union and Nonunion Sites of a Manufacturing Company

Layoffs and employment changes caused by current economic conditions have significant effects on employee work behavior and emotions as well as organizational outcomes. We examined the relationships between measures of job insecurity, organizational commitment, turnover, absenteeism, and worker performance within a manufacturer in Chapter 11 bankruptcy. A positive relationship was found between job insecurity and intentions to turnover, and a small negative correlation was found between measures of job insecurity and organizational commitment. Unobtrusive observations of union and nonunion performance over 4 months showed that nonunion production workers were on-task more frequently, although on-task behavior was high for both. Productivity and quality measures of different factories favored nonunion locations. Although comparisons between sites were constrained by a quasi-experimental design, repeated behavioral and outcome measures within sites showed differential effects when the company announced a plant closing in another state. Job insecurity appeared to be an establishing operation that produced differential effects between union and nonunion sites as well as among individual employees within sites.     

组织从经验中学习： 现状、问题、方向

组织从经验中学习是组织学习的重要方面.本文系统综述分析了前人在这方面的研究成果和观点,包括组织从经验中学习的模式、过程,组织从经验中学习的影响因素,组织从经验中学习的障碍,组织从经验中学习的成效等.分析了前人研究存在的缺陷:缺乏系统框架,缺乏深入机理,缺乏案例研究及对企业有实际指导意义的方法体系.针对这一系列的问题,文章提出了进一步的研究方向及框架.     

A step-by-step guide to the identification of an appropriate computer-aided production management system

The increasing dissatisfaction of users with their Computer-aided production management (CAPM) systems has been widely reported. This dissatisfaction led the UK's Science and Engineering Research Council to initiate a major study to improve CAPM systems use. The research results presented here form part of the overall initiative and focus on the development of a set of guiding principles for companies seeking to implement appropriate CAPM systems. The research team have identified three key elements that must be considered when implementing a CAPM system. First, that CAPM implementation can be eased if the overall manufacturing-system is first simplified. Second, we recognize that even then most companies will still require a computerized solution thus any methodology must include a software specification. Third, the overall performance of the system may be enhanced by changes to the infrastructure that supports the software. In attempting to meet these requirements the research team developed a four-stage methodology. The first two stages of the methodology deal primarily with the strategic context for CAPM, i.e. the simplification. The last two stages develop a software specification and present guidelines for the development of appropriate infrastructure configurations.     

New Organizational Forms for Competing in Highly Dynamic Environments: the Network Paradigm

Turbulence and rapid change in the business environment have been associated for some time with the development of new network organizational forms which put various types of strategic alliance and other inter-organizational collaborations into effect. This paper traces the rationale for the formation of such networks and the associated vertical disaggregation of functions and implications for internal organizational design. This leads to the proposal of a classification framework for network forms. Using the dimensions of volatility of environmental change on the one hand, and the type of inter-organizational relationship involved (collaborative or transactional) on the other hand, network forms are classified as: hollow networks, flexible networks, value-added networks and virtual networks. In each case it is possible to identify the environmental and organizational contingencies most likely to be associated with the emergence and adoption of a particular type of network arrangement. This argument leads to the identification of a new research agenda which has the goals of developing more robust conceptualizations of network characteristics; better understanding the contingencies surrounding the emergence of network forms and their relative efficiencies and specifying some of the major implications of network formation for internal organizational design. In parallel the paper identifies a number of managerial implications for setting strategic priorities and developing appropriate management systems in these new organizational contexts.     

The relationship between safety–production conflict and employee safety outcomes: Testing the impact of multiple organizational climates

Safety research is understandably dominated by studies examining the impact of organizational safety climate. Yet, other climates (e.g. service climate; productivity climate) that may also influence safety-related outcomes are rarely concurrently studied. Consequently, questions regarding how different organizational climates simultaneously affect employee safety attitudes and behaviours largely remain unanswered. Multilevel data collected from public transit employees indicated that safety–production conflict (SPC) was negatively related to accident-reporting attitudes and behavioural safety compliance. As expected, among employees in workgroups exhibiting a positive safety climate, the negative effect of SPC on behavioural safety compliance was attenuated. Moreover, a positive customer service climate reduced the negative effects of SPC on reporting attitudes; on the other hand, this relationship was exacerbated among workgroups with a high-productivity climate (i.e. those emphasizing on-time performance). The need for considering multiple aspects of an organizational climate is discussed in light of these results.     

Changes in production control required for untended operation of a flexible manufacturing cell

This article examines and improves the production control system of a firm that wants to operate its flexible manufacturing cell (FMC) in an untended third shift. The FMC consists of a machining centre, a pallet storage, a rail-guided transport vehicle for pallets and a clamping/unclamping station. The current production control system of the firm shows several deficiencies with respect to operating the FMC efficiently. This article proposes changes in the current production control hierarchy and introduces some new methods to solve major production control problems. The study illustrates the interaction between quantitative tools, organisational decisions and behavioural considerations. The approaches are general and can be used in other environments.     

Corporate governance and management practices: stakeholder involvement, quality and sustainability tools adoption

Local public services are the field in which New Public Management (NPM) and Public Governance issues are most in evidence. The local public services are characterized by the rethinking of the role played by local government in the provision of services. An evolution has taken place. From a traditional configuration in which local public services were managed by local governments they moved to a configuration where a separation has taken place between the local government role (which continues to be the guarantor of the satisfaction of public needs) and the role of local public utilities (LPUs) (responsible for delivering the services). This transformation implies both the delegation of resources and authority to lower organisational levels within the public sector and the reconfiguration of accountability chains between the state institutions and the society. In recent years, an intense debate has developed regarding the introduction of new tools and control systems. Particular attention has been paid to planning and control systems, human resources management systems, and performance management systems, leaving a few pioneers to develop their analysis on corporate governance mechanisms with regard their relationships with both the external (stakeholders) actors and the internal (management) ones. On one hand, the OECD wrote guidelines in order to ensure good corporate governance practices, focusing on relations with stakeholders. On the other hand, the dialogue between corporate governance and stakeholders has been already tackled by a number of International organizations guidelines or principles, following a debate on corporate governance that has progressively combined a stakeholder perspective with a more classic shareholder-maximizing model of governance. This article contributes to the debate on the stakeholder involvement process. By means of both a theoretical discussion and an empirical research conducted on 37 Italian LPUs, this paper attempts to analyse specific management tools which can be used to improve the quality of corporate governance in LPUs, by extending the stakeholder involvement. Some NPM’s tools, such as quality standards and sustainability tools imply an effort to offer new forms of organizational behaviour in the decision-making processes (i.e. the choice of the performance indicators and the reporting tools) and to create a dialogue between the enterprise and its stakeholders. In particular, in our study we focus on the adoption of quality standards (ISO 9000 and Customer Satisfaction) and sustainability tools (sustainability reports and ISO 14000 standard) as NPM’s tools to facilitate the stakeholder involvement practices.     

Product innovation input and outcome: moderating effects of the innovation process

In this research, we propose and examine the proposition that product innovation process is a moderator in the “innovation input–outcome” relationship. Innovation input involves R&D spending in relation to sales or R&D intensity. Innovation outcome involves innovation frequency or the number of new products developed and marketed. Innovation process involves the level of integration in organizational mechanisms: functional coordination, tool arrangement, and external relationship. Data from 45 medical and surgical device makers suggest that functional integration is a significant moderator in the innovation input–outcome relationship. External integration has only main effects whereas tool integration has neither main nor interaction effects on innovation frequency. Results could, however, be industry and sample specific. We discuss the implications of these findings for product innovation theory and research.     

The evolution of organizations and leadership from the ancient world to modernity: A multilevel approach to organizational science and leadership (OSL)

The purpose of this paper is to offer an initial theory, timeline, and taxonomy for discussing and researching the evolution of types of organizations and the concomitant context they provide for leadership. Specifically, leadership roles in the ancient world and modernity are contrasted and found to be almost diametrically opposed. To arrive at this conclusion, this work draws upon current extensions of evolutionary theory from biology and psychology to organizational studies and leadership (Yammarino & Dansereau, 2011). This framework is then contrasted with Kellerman (2012) who calls for an end to leadership studies. The question this paper attempts to address is: from a multi-level perspective, how have evolutionary changes in the types of commercial organizational structures led to differing dominant leadership styles? Without having to call for an end to leadership studies, an understanding of ancient forms of organization can lend insight into a number of contemporary business and geopolitical conflicts where tribalism is a factor.