Managing Differentiation‐Integration Duality in Supply Chain Integration*

Existing research focuses on the positive returns to operational performance of firms’ supply chain integration (SCI) with suppliers, buyers, and customers. We draw on differentiation‐integration duality and contingency theory to suggest that manufacturing firms should seek to achieve both integration through supply chain coordination activities and differentiation through modularity‐based manufacturing practices (MBMP). Using a sample of 261 manufacturing firms, we identify an inverse U‐shaped relationship between SCI and operational performance. Furthermore, we find support for the importance of differentiation‐integration duality as a fit between high levels of SCI and high levels of MBMP results in enhanced operational performance. We find support for a contingency perspective as fit is especially critical at higher levels of environmental uncertainty. Implications for theory, practice, and further research are suggested.     

The Impact of Organizational Culture on Time‐Based Manufacturing and Performance

Firms are utilizing an array of manufacturing practices in their quest for survival and success in the marketplace. The implementation of those practices has not always resulted in success stories as the focus had been mostly on technical issues, with little concern for “soft issues.” For example, the enabling role of organizational culture has often been ignored. Using Schein's conceptualization of culture as underlying assumptions, espoused values, and artifacts, we examine a framework that relates culture and manufacturing practices to performance. The underlying assumption of customer orientation is posited to affect espoused values such as beliefs on investing in facilities and equipment to leverage intellectual work and to promote creativity, beliefs on working with others, beliefs on making decisions that are global, beliefs on management control, and beliefs on integrating with suppliers. The espoused values are hypothesized to affect visible attributes of culture (behaviors) such as time‐based manufacturing practices, which firms are employing for competitive advantage. A sample of 224 firms is used for developing research instruments and testing the hypothesized relationships advanced. Results indicate that high levels of customer orientation lead to a set of managerial beliefs that are collaborative and integrative. In turn, certain espoused values support a high level of time‐based manufacturing practice, which leads to high performance.     

Order Management in the Customization‐Responsiveness Squeeze*

Make‐to‐order (MTO) products may be either customized or standard, and customization can occur either at the configuration or component level. Consequently, MTO production processes can be divided into three customization gestalts: non‐customizers, custom assemblers, and custom producers. In this article, we examine how the multilevel nature of customization affects order management in processes that produce complex MTO products. We first empirically validate the existence of the three customization gestalts and subsequently, analyze the order management challenges and solutions in each gestalt in a sample of 163 MTO production processes embedded in seven different supply chains. In the analyses, we follow a mixed‐methods approach, combining a quantitative survey with qualitative interview data. The results show that important contingencies make different order management practices effective in different gestalts. Further qualitative inquiry reveals that some seemingly old‐fashioned practices, such as available‐to‐promise verifications, are effective but commonly neglected in many organizations. The results also challenge some of the conventional wisdom about custom assembly (and indirectly, mass customization). For example, the systematic configuration management methods—conventionally associated with project business environments—appear to be equally important in custom assembly.     

Linking Work Design to Mass Customization: A Sociotechnical Systems Perspective*

Mass customization has gained increasing importance in recent years due to its ability to provide customized products efficiently and effectively, and manufacturing companies are continuously searching for ways to develop their mass‐customization ability. Despite extensive literature focusing on mass customization, few studies have systematically examined the impact of work‐design practices on a company's mass‐customization ability. Using the Sociotechnical Systems theory as a foundation, we link work‐design practices with mass‐customization ability, specifically identifying ten work‐design practices and examining their impact on mass‐customization ability using survey data and empirical research methods. The results support our hypothesized links and suggest that work‐design practices that manage both the technical and the social dimensions for achieving organization success have significant impact on a company's ability to achieve mass customization.     

Investigating the Level of End‐User Development and Involvement Among Time‐Based Competitors

As global markets and technology change, time‐based competitors create product development and manufacturing practices that reduce response time and enhance customization capabilities. These practices require an information‐rich internal environment that is capable of flexible resource deployment and direct and continuous feedback. To build this environment, time‐based competitors are developing end‐user capabilities and involving them in information systems (IS) activities. Data collected from 265 manufacturers were used to determine if firms with high levels of time‐based product development and time‐based manufacturing practices also have high levels of end‐user involvement in IS‐related activities, end‐user training effectiveness, and end‐user computing skills. The results of this study support that contention.     

Customer Learning Processes,Strategy Selection,and Performance in Business‐to‐Business Service Firms*

Learning about customers takes place through relevant dialogues with those customers, also known as customer relationship management (CRM). As relationships develop, information about the customer is gathered in the firm's customer information systems (CIS): the content, processes, and assets associated with gathering and moving customer information throughout the firm. This research develops a measure of CIS management capabilities based on learning organization theory and measured by the ability to get, store, move, and use information throughout the business unit. This measure is then used to analyze customer learning processes and associated performance in the context of marketing strategic decision making. This study of 209 business services firms finds that generic marketing strategy positioning (low‐cost and differentiation) and the marketing tactics of personalization and customization are related to CIS development. Customer information systems development in turn is associated with higher levels of customer‐based performance, which in turn is associated with increased business growth. Since the strongest association with customer‐based performance is strategy selection, the long‐term benefits of the knowledge gained from the CIS may be in the ability to assist in measuring customer‐based performance, rather than in the ability to immediately contribute to performance. Finally, for these firms, customization and personalization are not directly associated with performance and thus may not be necessary to support every firm's marketing strategy.     

Lowest Cost May Not Lower Total Cost: Using “Spackling” to Smooth Mass‐Customized Production

Consider a manufacturer who mass customizes variants of a product in make‐to‐order fashion, and also produces standard variants as make‐to‐stock. A traditional manufacturing strategy would be to employ two separate manufacturing facilities: a flexible plant for mass‐customized items and an efficient plant for standard items. We contrast this traditional focus strategy with an alternative that better utilizes capacity by combining production of mass‐customized and standard items in one of two alternate spackling strategies: (1) a pure‐spackling strategy, where the manufacturer produces everything in a (single) flexible plant, first manufacturing custom products as demanded each period, and then filling in the production schedule with make‐to‐stock output of standard products; or (2) a layered‐spackling strategy, which uses an efficient plant to make a portion of its standard items and a separate flexible plant where it spackles. We identify the optimal production strategy considering the tradeoff between the cost premium for flexible (versus efficient) production capacity and the opportunity costs of idle capacity. Spackling amortizes fixed costs of capacity more effectively and thus can increase profits from mass customization vis‐à‐vis a focus strategy, even with higher cost production for the standard goods. We illustrate our framework with data from a messenger bag manufacturer.     

Impact of Information Technology Integration and Lean/Just‐In‐Time Practices on Lead‐Time Performance*

Managers seeking to improve lead‐time performance are challenged by how to balance resources and investments between process improvement achieved through lean/just‐in‐time (JIT) practices and information technology (IT) deployment. However, extant literature provides little guidance on this question. Motivated by both practical importance and lack of academic research, this article examines empirically the relationships among interfirm IT integration, intrafirm IT integration, lean/JIT practices, and lead‐time performance using data from IndustryWeek's Census of Manufacturers ( IndustryWeek, 2006 ). The results provide several new insights on the relationship between IT integration and lean/JIT practices. First, the study confirms that implementing lean/JIT practices significantly reduces lead time. Second, lean/JIT practices mediate the influence of IT integration on lead‐time performance. This suggests that process improvements that result from lean/JIT practices are important contributors to the success of IT integration. Even companies that have experienced success in reducing lead time through lean/JIT practices may benefit from IT integration practices such as those embodied in enterprise resource planning systems. The findings provide managers with empirical evidence and a theoretical framework on the balance between lean/JIT and IT for effecting improvement in lead‐time performance, thus offering practical guidance on this important question. Future research is needed to extend the lean/JIT practices in this study to supply chain practices and explore the relationship between supply chain practices and IT integration.     

The Impact of Organizational Structure on Mass Customization Capability: A Contingency View

This study investigates the role of organizational structure in facilitating the development of mass customization (MC) capability in various manufacturing settings. Specifically, three dimensions of organizational structure are considered—flatness, centralization, and employee multifunctionality. We model organizational structure as a second‐order factor whose value is captured on a mechanistic‐organic continuum, where the organic form is characterized by a flat, decentralized structure with a wide use of multifunctional employees. We propose that a positive relationship exists between the organic organizational structure and MC capability. Additionally, building upon contingency theory, we argue that this positive relationship is moderated by mass customizer type—full mass customizers, which customize products at the design or fabrication stage of the production cycle, versus partial customizers, which customize products only at the assembly or delivery stages. Based on a study of 167 manufacturing plants from three industries and eight countries, we find that, for the overall sample, organic structure plays a significant role in enabling firms to pursue MC capability. However, an analysis of full versus partial mass customizers shows that the positive impact of organic structure on MC capability is statistically significant only for full mass customizers, not for partial mass customizers.     

PRODUCT OFFERING,PRICING, AND MAKE‐TO‐STOCK/MAKE‐TO‐ORDER DECISIONS WITH SHARED CAPACITY

In an era of mass customization, many firms continue to expand their product lines to remain competitive. These broader product lines may help to increase market share and may allow higher prices to be charged, but they also cause challenges associated with diseconomies of scope. To investigate this tradeoff, we considered a monopolist who faces demand curves, which for each of its potential products, decline with both price and response time (time to deliver the product). The firm must decide which products to offer, how to price them, whether each should be make‐to‐stock (mts) or make‐to‐order (mto), and how often to produce them. The offered products share a single manufacturing facility. Setup times introduce disceonomies of scope and setup costs introduce economies of scale. We provide motivating problem scenarios, model the monopolist's problem as a non‐linear, integer programming problem, characterize of the optimal policy, develop near‐optimal procedures, and discuss managerial insights.     

From Customer‐Oriented Strategy to Organizational Financial Performance: The Role of Human Resource Management and Customer‐Linking Capability

Drawing on the organizational capabilities literature, the authors developed and tested a model of how supportive human resource management (HRM) improved firms’ financial performance perceived by marketing managers through fostering the implementation of a customer‐oriented strategy. Customer‐linking capability, which is the capability in managing close customer relationships, indicated the implementation of the customer‐oriented strategy. Data collected from two emerging economies – China and Hungary – established that supportive HRM partially mediated the relationship between customer‐oriented strategy and customer‐linking capability. Customer‐linking capability further explained how supportive HRM contributed to perceived financial performance. This study explicates the implication of customer‐oriented strategy for HRM and reveals the importance of HRM in strategy implementation. It also sheds some light on the ‘black box’ between HRM and performance. While making important contributions to the field of strategy, HRM and marketing, this study also offers useful practical implications.     

Product sequencing in multiple-piece-flow assembly lines

Modern markets demand mass customization, that is, the manufacture of customized products at low cost. Mass customization represents a major challenge for the organization of assembly lines, which were originally designed for the manufacture of homogeneous products. The multiple-piece-flow assembly line is an organizational innovation that can address this challenge. Here, several customized workpieces, each associated with a separate customer order and, hence, a separate due date, are handled simultaneously in one cycle. Consequently, the idle times decrease as do the manufacturing costs. Multiple-piece-flow assembly lines are used, for instance, in manufacturing industrial equipment.To the best of our knowledge, this paper is the first to investigate product sequencing in multiple-piece-flow assembly lines. We formalize the underlying planning problem, establish a mixed-integer model, examine its relation to several classic optimization problems, and describe useful problem properties. We leverage these properties to design an effective iterative variable neighborhood heuristic (IVNH). A detailed simulation based on real-world data and the rolling-horizon planning framework confirms that the IVNH is well suited for practical use. Furthermore, extensive computational experiments on well-structured randomly generated data sets show that the IVNH identifies optimal or near-optimal solutions within short run times. It outperformed an off-the-shelf optimization software, and in certain practice settings, the IVNH was even able to substantially reduce average order delays.     

A Contingent View of Quality Management‐The Impact of International Competition on Quality

Much of the research on quality practices and performance reflects a resource‐based perspective of the firm, dealing primarily with internal issues of managerial and technological competence in developing and executing an effective TQM strategy. The neoclassical perspective on the influence of the competitive environment on quality practices and performance remains conspicuously absent in the empirical quality literature. Our study aims to address this gap by examining the contingent role of international competition on quality management and performance. We develop and test an integrative framework of quality management, consisting of high involvement work practices, quality practices, quality performance, and firm performance. We then examine the contingent effects of international competition on the constructs and relationships of the framework. International competition was found to moderate the relationship between quality practices and customer satisfaction performance, as well as the relationship between high involvement work practices and firm performance. The moderator effects suggest interesting implications for quality theory and practice.     

Service Architecture and Modularity*

An understanding of the nature of service architecture and modularity is crucial to service design and innovation. Two sets of approaches are developed that further our understanding and support decision making. First is a systematic decomposition approach to architecture modeling that allows organizations to understand their current architecture, evaluate alternative architectures, and identify key interfaces between different parts of the service. Second, the article develops a service modularity function (SMF), a mathematical model indicating the degree of modularity deriving from unique services and the degree to which the modules can be replicated across a variety of services. Three areas are identified that can contribute to competitiveness: the possession of unique service modules or elements not easily copied in the short term by competitors; the ability to exploit these through replication across multiple services and/or multiple sites; and the presence of a degree of modularity, which in turn supports both customization and rapid new product development. The SMF can support decision making in the design of services and the exploitation of service innovation. In particular, the relationship between architecture and modularity and the roles of service contact personnel in the customization of services is shown to be complementary. It is proposed that service customization can be either combinatorial (the combination of a set of service processes and products to create a unique service) or menu driven (the selection of one or more services from a set of existing services/products to meet customer needs).     

Interpretive structural modeling-based framework for mass customisation enablers: an Indian footwear case

Abstract

In the epoch of open economy and with the emergence of availability of individualised products over the Internet, Indian manufacturing industries are facing an enormous pressure to become more flexible and responsive, to accomplish customer’s varied and increasing demands. Mass customisation (MC) is about developing a customised product on demand for a particular customer after reception of a real order and producing it with the similar operational efficiency as one would anticipate from a mass-produced product. MC takes into account the merits of both the earlier systems of production, i.e. mass production and craft production. The craft production satisfies the personalised demands of customers and the mass production produces a limited variety of products at lower cost. Industries in developing countries such as India confront pressure from several perspectives to adopt MC. This study has been presented in the context of Indian manufacturing industries, and particularly for footwear industries to examine the enablers of MC. Achieving MC, however, require certain enabling technologies and processes in place. Several such enablers have been identified from the research literature. The objective of this study it to key out significantly important enablers for MC using interpretive structural modelling (ISM), and develop a hierarchy of these enablers for the Indian footwear units. ISM results show that modularity-based practices, digital manufacturing practices and supply chain integration are the most important MC enablers. Enhanced flexibility and responsiveness in the footwear production system can be achieved through modular and reconfigurable production system.     

A Capacitated Multi‐echelon Inventory Placement Model under Lead Time Constraints

We develop an inventory placement model in the context of general multi‐echelon supply chains where the delivery lead time promised to the customer must be respected. The delivery lead time is calculated based on the available stocks of the different input and output products in the different facilities and takes into account the purchasing lead times, the manufacturing lead times, and the transportation lead times. We assume finite manufacturing capacities and consider the interactions of manufacturing orders between time periods. Each facility manages the stocks of its input and output products. The size of customer orders and their arrival dates and due dates are assumed to be known as in many B2B situations. We perform extensive computational experiments to derive managerial insights. We also derive analytical insights regarding the manufacturing capacities to be installed and the impacts of the frequency of orders on the system cost.     

Perceived Value of the Mass‐Customized Product and Mass Customization Experience for Individual Consumers

The operations management literature on mass customization mainly focuses on the questions of whether and how manufacturers can efficiently deliver customization. Researchers have analyzed the trade‐offs between customization and dimensions of operational performance such as delivery times, quality, and costs. However, we argue that providing efficient customization is not sufficient per se to assess the value of mass customization. From this perspective, this paper focuses on complementary mechanisms for creating value: the benefits perceived by individual consumers. Two global components of perceived value within the context of mass customization are identified: mass‐customized product, with three dimensions, and mass customization experience, with two dimensions. The Consumer‐Perceived Value Tool (CPVT) is proposed to empirically measure the five perceived benefits related to the mass‐customized product and to the codesign process from the consumer viewpoint. The psychometric properties of the CPVT are assessed using three samples. The implications of this approach are discussed, along with directions for further research.     

Customer‐Base Concentration and Inventory Efficiencies: Evidence from the Manufacturing Sector

What is the link between customer‐base concentration and inventory efficiencies in the manufacturing sector? Using hand‐collected data from 10‐K Filings, we find that manufacturers with more concentrated customer bases hold fewer inventories for less time and are less likely to end up with excess inventories, as indicated by the lower likelihood and magnitude of inventory write‐downs and reversals. Using disaggregated inventory disclosures, we find that inventory efficiencies primarily flow through the finished goods inventory account, while raw material efficiencies are offset by higher work‐in‐process holdings and longer work‐in‐process cycles. In additional analysis, we document a valuation premium for more concentrated manufacturers after controlling for other firm characteristics, including default risk and cost of capital estimates. We conclude that investors trade off the costs and benefits of relationships with a limited number of major customers and, on balance, consider customer‐base concentration as a net positive for firm valuation. Overall, our study adds to interdisciplinary research in accounting and operations management by shedding new light on the relevance of major customer disclosures for fundamental analysis and valuation in the manufacturing sector.     

From Mass Production to Mass Customization: Hindrance Factors,Structural Inertia,and Transition Hazard

Research on mass customization has largely overlooked the issue of organizational change associated with the mass production‐to‐mass customization transition. To address this gap in the literature, we conduct a longitudinal case study of a manufacturing facility belonging to a division of a Fortune 1000 discrete manufacturing firm as it seeks to transition from mass production to mass customization. We empirically identify five factors hindering the mass production‐to‐mass customization transition within the research site and articulate five corresponding generalizations explaining how and why these hindrance factors relate to the mass production‐to‐mass customization transition hazard beyond the research site (i.e., how and why the five hindrance factors, in general, threaten the likelihood of a successful mass production‐to‐mass customization transition). We then theoretically validate the five hindrance factors and corresponding generalizations by mapping them onto the antecedents and tenets of structural inertia theory. We conclude with a brief discussion of the scientific and pragmatic significance of the findings and highlight opportunities for future research.     

Customization: Impact on Product and Process Performance

Manufacturing capability has often been viewed to be a major obstacle in achieving higher levels of customization. Companies follow various strategies ranging from equipment selection to order process management to cope with the challenges of increased customization. We examined how the customization process affects product performance and conformance in the context of a design‐to‐order (DTO) manufacturer of industrial components. Our competing risk hazard function model incorporates two thresholds, which we define as mismatch and manufacturing thresholds. Product performance was adversely affected when the degree of customization exceeded the mismatch threshold. Likewise, product conformance eroded when the degree of customization exceeded the manufacturing threshold. Relative sizes of the two thresholds have management implications for the subsequent investments to improve customization capabilities. Our research developed a rigorous framework to address two key questions relevant to the implementation of product customization: (1) what degrees of customization to offer, and (2) how to customize the product design process.