Relationships among JIT practices: an interpretive modeling approach

Abstract

This research develops a model of relationships among components of Total-JIT, including JIT-information, JIT-manufacturing, JIT-purchasing, and JIT-selling, to establish an implementation hierarchy based on relative importance. The data collected relates to the relationships among JIT components and two performance measures, supply chain competency and organizational performance. Two groups are used in the research, one group of five operations management academics and another group of 30 practicing operations managers working in U.S. manufacturing firms. An interpretive structural modelling methodology is used to develop alternative structural models. The academics’ data show JIT-information emerging as lynchpin of relationships, directly impacting all other JIT practices and both performance measures. The practitioners’ data indicates that all JIT practices and performance measures are interactive as components and outcomes. This study is the first to apply interpretive structural modelling to investigate the interplay among total-JIT components and the performance measures of supply chain competency and organizational performance.     

Supply chain relationship quality and its impact on firm performance

Abstract

This paper examines the impact of supply chain relationship quality (SCRQ) on firm performance (FP) through the mediators of supply chain management processes (SCMP) and supply chain performance (SCP). In the literature, these linkages have been examined separately; in contrast, this study takes a holistic perspective on the antecedents of FP. The model was tested using survey data from manufacturing companies. Variance-based structural equation modelling revealed that both SCMP and SCP lead to FP, unlike SCRQ. On the other hand, SCRQ affects SCMP. Drawing on the resource-based view, consistency in SCRQ can lead to not only efficient and effective supply chain management but also improvements in FP and SCP. This research has practical implications, providing supply chain decision makers with insights on enhancing FP. Supply chain decision makers will be able to benefit from the findings of our study by improving supply chain relationships with supply chain members and ensuring FP. This research also highlights how effective management of SCRQ, SCMP and SCP can provide better FP and a competitive advantage.     

Reengineering of a supply chain management system: A case study

A business process reengineering (BPR) project concerning a supply chain management (SCM) system of a heavy machinery manufacturing company has been discussed in this paper. The BPR implementation process model has been described. The principal objective of this project has been to bring about radical changes in the mind sets, management styles and systems of a very mature but large organization in India. The implementation process has been very successful because the model has been explored by an organizational development initiative. BPR is both feasible and worthwhile in business only when ideas and ideals are put willingly in practice; and is practised in a collaborative mode to get closer to the people, especially at the floor level, and to customers and suppliers.     

An information system for Just-In-Time

In recent years, U.S.'s worldwide industrial and economic leadership has been seriously challenged by many foreign countries. In order to counter the problem, many U.S. manufacturing companies have sought effective materials management systems such as MRP and the ‘Just-In-Time’ (JIT) system as used by many Japanese companies. Even through many practitioners and academicians have been studying the JIT concept and have recommended ways of adapting the concept to the U.S. manufacturing environment, not very many organizations are enjoying benefits of JIT system in full scale because of misunderstanding of information needs in JIT system. The objectives of this paper are (1) to identify information requirements of the materials management systems under JIT concept, (2) to compare them against the requirements under MRP system, and (3) to propose an integrated management information system to support materials management system in JIT environment. The goal of this paper is to facilitate more effective implementation of the JIT system, and stimulate further research on the subject matter.     

Experimental earliness/tardiness production planning with the due window system

In order to use the philosophy of JIT to improve the production planning method of MRP-II, we propose the experimental software system of the earliness/tardiness produc tion planning problem with due window. By means of the approaches and model reported in this paper, the optimal production planning can be achieved. The recommended model extends the problem of due window from the shop scheduling level into the aggregated planning level of mass manufacturing systems. Simulation results have demonstrated that the experimental software is a useful tool for the production management of repetitive manufacturing enterprises.     

Some structural properties for the just-in-time level schedule problem

Just-in-time (JIT) is a pull concept applied mainly in repetitive manufacturing systems, and it is characterized by a scenario where only the required units are produced in the required quantities at the required times. It particularly aims at eliminating wastes associated with inventories in the system. A level schedule is desirable for a JIT assembly system, as it serves as an approximation for all forms of smoothing. The min-sum formulation of the assembly line level schedule problem is one of those that has been mainly used in the literature. Using this formulation as a base, we develop some useful structural properties for the problem. Among other things, it is shown that a level schedule would tend to be more difficult to achieve for products (models) with comparatively fewer units in the products composition structure.     

An approach to learning from both good and poor factory performance in a Kanban-based just-in-time production system

In a JIT manufacturing environment it may be desirable to learn from an archived history of data that contains information that reflects less than optimal factory performance. The purpose of this paper is to use rule induction to predict JIT factory performance from past data that reflects both poor (saturated or starved) and good (efficient) factory performance. Inductive learning techniques have previously been applied to JIT production systems (Markham et al. , Computers and Industrial Engineering, 34 , 717-726, 1998; Markham et al. , International Journal of Manufacturing Technology Management, 11 (4), 239-246, 2000), but these techniques were only applied to data sets that reflected a well-performing factory. This paper presents an approach based on inductive learning in a JIT manufacturing environment that (1) accurately classifies and predicts factory performance based on shop factors, and (2) identifies the important relationships between the shop factors that determine factory performance. An example application is presented in which the classification and regression tree (CART) technique is used to predict saturated, starved or efficient factory performance based on dynamic shop floor data. This means that the relationship between the variables that cause poor factory performance can be discovered and measures to assure efficient performance can then be taken.     

Manufacturing in the Nineties By H.J. STRUDEL and P.DESRUELLE(Van Nostrand Reinhold,New York, 1992). £31.50.

Abstract

Looking for a world model for the manufacturing information flow diagram has brought us to the conclusion that it is impossible to build an all-encompassing, all-inclusive system. The redundancy and overlap would make the system excessively complex and ineffective. The best way to generalize a model of this type is to simplify. The result is that we eliminate nearly the entire production control mechanism that is found in the labour intensive MRP system (Fig. 1). We come up with a system that is much closer to the material intensive JIT system (Fig. 2). The conclusion is that effective production control requires that you choose which resource you wish to optimize, and then select a system that controls the plant around the selected resource base. This is the function of books like International Management and Production. A second conclusion would be that complexity (MRP—Fig. 1) gains very little over simplicity (JIT—Fig. 2 or World Model—Fig. 4) in productivity or efficiency. As Shozo Hibino says in his book Breakthrough Thinking, we need to run our plants smarter, not harder.     

Managing knowledge in supply chains: a catalyst to triple bottom line sustainability

Abstract

Sustainable supply chain management (SSCM) and knowledge management’s (KM) positive role in improving supply chain development and performance have both attracted attention in recent years, the former arguably stimulated by the triple bottom line (TBL). Despite the positive development, there is a paucity of theoretical and empirical studies identifying the broad capabilities that affect a firm’s ability to simultaneously pursue economic, environmental and social success. We use the natural-resource-based (NRBV) and knowledge-based (KBV) views to develop a series of propositions linking KM capability to strategic and operational supply chain sustainability and competiveness and test their veracity with practicing managers (n?=?275). We offer a systematic analysis of KM’s role in the development of SSCM. The findings confirm the credibility of the theoretical propositions and identify how different KM processes specifically facilitate strategic or operational development of SSCs. We provide researchers with a framework to guide future research at the KM/TBL nexus.     

The roles of supply network centralities in firm performance and the moderating effects of reputation and export-orientation

Abstract

This study explores how supply network degree, closeness, and betweenness centralities affect firm performance, and the moderating effects of organizational reputation (measured by PageRank centrality) and export-orientation. The supply chain relationship empirical data are drawn from manufacturing and manufacturing service companies in Hong Kong, China. Social network analysis and moderated regression analysis were adopted to test the hypotheses for a sample of 814 focal firms with 3086 supply chain ties. The results indicate that in-degree and closeness centralities improve firm performance. Reputation is found to positively moderate the relationship between closeness and sales performance, but negatively moderates the relationship between betweenness and sales performance. Export-orientation has no effect on relationships. This study contributes to the literature by providing additional empirical evidence on the role of supply network position in firm performance. It also introduces PageRank centrality as a new measure of organizational reputation in a supply network.     

A knowledge chain management framework to support integrated decisions in global supply chains

Knowledge management has been identified as a key enabler to achieve organisation’s value chain competitiveness. It, however, has been facing fresh challenges in a global supply chain setting. This paper proposes a global knowledge chain management (GKCM) framework that identifies and prioritises critical knowledge that a global supply chain can focus on to support integrated decisions. The framework explores three types of global context knowledge, namely global market knowledge, global capacity knowledge and global supply network configuration knowledge. Empirical study has been undertaken within the manufacturing industry to evaluate the GKCM framework. Analytic network process has been explored as a key method to assess the importance of the global knowledge constructs from supply chain managers’ perspectives. A key contribution of the paper is that it advances existing knowledge chain management approaches within one organisation and its local supply chain to include the global context knowledge applicable to global manufacturing settings, and highlights how the GKCM framework can support global supply chain integrated decisions.     

The impact of critical success factors of JIT implementation on organizational performance

Much has been written and publicized about the virtues of JIT philosophies during the past decade. However, relatively limited empirical research has been reported con-cerningJIT implementation on organizational performance. This study presents the results of an empirical study which utilized both concrete financial accounting data and a broad cross-sectional survey as measures of organizational performance to determine the impact of each JIT implementation requirement factor to organizational performance. Communication between production and marketing departments was identified as a critical factor for increased inventory turnover and work-in-process inventory turnover, while employees' participation and the bottom-up management approach were determined as significant factors for improving quality and flexibility. The results of this study imply that in JTT environment personnel management practices, such as bottom-up management encouraging employees participation, and organization management such as a communications linking the production and marketing departments, are more important than JIT practices themselves.     

Computational complexity of algorithms for MRP and JIT production planning problems in enterprise resource planning systems

An enterprise resource planning system (ERP) is the information backbone of many manufacturing companies. At the core of ERP is a conventional material requirements planning (MRP) production planning system or a variation of MRP when just-in-time (JIT) principles are used in manufacturing. MRP and JIT both organize production planning into a hierarchy of long-, medium- and short-range problems. In all there are eight different problems. Some are common to MRP and JIT, others are specialized for a particular system. This paper analyses the computational requirements of these problems. This is important for ERP because it plans for large numbers of products (e.g. 50 000 products at 3M Company and 44 000 products at States Industries in Oregon) at large numbers of locations (e.g. 82 locations in 21 countries for Visteon Automotive Systems of Michigan and 19 locations at Boeing). We show that adequate algorithms exist for some problems, but better algorithms are needed for other problems if ERP is to provide useful production plans.     

Quality management and performance: a comparison between the UK and Turkey

Purpose: The aim of this article is to detail the correlation between quality management, specifically its tools and critical success factors, and performance in terms of primary operational and secondary organisational performances.

Design/methodology/approach: Survey data from the UK and Turkey were analysed using exploratory factor analyses, structural equation modelling and regression analysis.

Findings: The results show that quality management has a significant and positive impact on both primary and secondary performances; that Turkish and UK attitudes to quality management are similar; and that quality management is widely practised in manufacturing and service industries but has more statistical emphasis in the manufacturing sector. The main challenge for making quality management practice more effective lies in an appropriate balanced use of the different sorts of the tools and critical success factors.

Originality/value: This study takes a novel approach by: (i) exploring the relationship between primary operational and secondary organisational performances, (ii) using service and manufacturing data and (iii) making a cross-country comparison between the UK (a developed economy) and Turkey (a developing economy).

Limitations: Detailed contrast provided between only two countries.     

Cloud manufacturing system for sheet metal processing

Abstract

Cloud computing is changing the way industries and enterprises run their businesses. Cloud manufacturing is emerging as an approach to transform the traditional manufacturing business model, while helping the manufacturer to align production efficiency with its business strategy, and creating intelligent factory networks that enable collaboration across the whole enterprise. Many production planning and control (PPC) problems are essentially optimisation problems, where the objective is to develop a plan that meets the demand at minimum cost or maximum profit. Because the underlying optimisation problem will vary in the different business and operation phases, it is important to think about optimisation in a dynamic mechanism and in a number of interlinked sub-problems at the same time. Cloud manufacturing has the potential to offer decision support as a service and medium of communication in PPC. To solve these problems and produce collaboration across the supply chain, this paper provides an overview of the state of the art in cloud manufacturing and presents a model of cloud-based production planning and production system for sheet metal processing.     

A high-quality-supplier selection model for supply chain management and ISO 9001 system

Supplier selection process for supply chain management (SCM) and ISO 9001 quality management system environments is considered. Determining suitable suppliers in the supply chain has become a key strategic consideration. However, the nature of these decisions is usually complex and unstructured. This paper proposes a high-quality-supplier selection (HQSS) model to deal with supplier selection problems in supply chain management. In selecting a supplier, quality management factors are considered first, and then price, delivery, etc. Quality management factors include a quality management audit, product testing, engineering work force, capability index, training time, etc., based on a five-interval scale. Next, the HQSS model determines the final solution by considering factors such as price, production lead-time, and delivery time.     

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.     

Understanding the emergence of redistributed manufacturing: an ambidexterity perspective

Abstract

This paper extends operations strategy theory on efficiency and flexibility trade-offs to the emergent phenomenon of redistributed manufacturing (RDM). The study adopts a multiple-case design including five small and five large pharmaceutical firms. We propose that organizations can gain the efficiency benefits of centralized manufacturing and the flexibility advantages of RDM by building an ambidexterity capability. To build such a capability, large firms can structurally partition their manufacturing and supply management functions, with one sub-unit managing centralized production and the other RDM. Smaller enterprises can build an ambidexterity capability by creating the right organizational context, where multi-skilled workers switch between efficient and flexible tasks. This paper contributes to theory by explaining the emergence of RDM using an organizational ambidexterity lens, laying the groundwork for new theory development in the field. We provide managers with a practical example of how to build an ambidexterity capability to realize flexibility and efficiency advantages.     

Development and validation of a lean supply chain management measurement instrument

It is widely argued that to be competitive, a company not only needs to focus on internal aspects but on the entire supply chain. Lean supply chain management has become a means of enhancing competitiveness by improving efficiency and increasing flexibility at all stages of the supply chain. This research develops and validates a lean supply chain management measurement instrument. A two-phase approach is used for scale development and refinement. In the first phase, a literature review is conducted to identify definitions of lean supply chain management and agile supply chain management and their corresponding measurement items. In the second phase, the lean supply chain management measurement instrument is validated using survey data based on scales developed in the first phase by 59 scholars with experience in lean management and/or supply chain management. The results provide a structured and comprehensive measure of lean supply chain management indicating that there are two differentiated dimensions in the measurement instrument: one related to the operational aspects of lean supply chain strategy implementation and the second related to lean supply chain planning.     

A combined optimization and agent-based approach to supply chain modelling and performance assessment

The main objective of this paper is to give an example of how expert systems techniques for distributed decision-making can be combined with contemporary numerical optimization techniques for the purposes of supply chain optimization and to describe the resulting software implementation. In this paper, multi-agent modelling techniques are applied to simulate and control a simple demand-driven supply chain network system, with the manufacturing component being optimized through mathematical programming. The system measures supply chain performance and the effect of different parameters in the replenishment control system, and can be used to simulate the behaviour of a system that uses optimization for part of its decision-making. The objective of this supply chain network system is to reduce operating cost, while maintaining a high level of customer order fulfilment.