Linking IT Applications with Manufacturing Strategy: An Intelligent Decision Support System Approach

Research has indicated the importance of matching Information Technology (IT) applications or manufacturing systems with the competitive strategy of a company. Selection of the right type of IT application is, however, a challenging task. When a company with a given dominant process structure emphasizes two or more competitive priorities, such as quality, product flexibility, etc., an unaided manager faces a complex decision problem in choosing from alternative IT applications available in the areas of product design through distribution. In this paper, we develop an Intelligent Decision Support System (IDSS) to assist managers with assessment of the relative importance of competitive priorities in their organization, evaluation of the fit between the competitive priorities and their dominant process structure, and identification of the IT applications that are consistent with both the competitive priorities and the process structure. The IDSS is comprised of an interactive user interface, a knowledge database, a decision model, and a Knowledge-Based System (KBS) that was developed using the 1st Class KBS shell. Validation of the system illustrates that its performance is as good as the human expert, and it has the potential to facilitate effective and swift decision making in the selection of appropriate IT applications that best match an organization's manufacturing strategy. The choice and use of the right type of IT application should provide a company with a competitive edge.     

The Influence of Cost and Quality Priorities on the Propensity to Outsource Production*

Outsourcing of production has escalated over the past decade due to unprecedented competition and worldwide access to low‐cost labor markets. This article examines how cost and quality priorities—two key attributes of manufacturing strategy—influence a manufacturer's propensity to outsource. By doing so, we bridge the existing gap between research on manufacturing strategy and firm boundaries. We develop a theory‐based model that links a manufacturer's cost and quality priorities to its plans to outsource production. Our empirical analyses, based on survey data obtained from 867 manufacturing business units, control for firm‐specific factors previously shown to impact outsourcing, including asset specificity, uncertainty, and current capabilities in cost and quality. We found that the competitive priority placed on cost played an integral role in sourcing decisions, while, surprisingly, conformance quality priorities did not. The cost result is consistent with our expectations and observations in practice. The significant effect of cost priority on outsourcing shows that any theory of firm boundaries that fails to consider competitive priorities is incomplete. The finding regarding quality, which was counter to our expectations, may partially explain why there is an emergence of so many nonconforming products associated with outsourcing. Taken together, our results provide theoretical insights for future research into how manufacturing managers can improve their decision making on outsourcing production.     

COMPETITIVE PRIORITIES: INVESTIGATING THE NEED FOR TRADE‐OFFS IN OPERATIONS STRATEGY

A heated debate continues over the need for trade‐offs in operations strategy. Some researchers call for plants to focus on a single manufacturing capability and devote their limited resources accordingly, while others claim that advanced manufacturing technology (amt) enables concurrent improvements in quality, cost, flexibility, and delivery. Yet there is little empirical evidence for or against the trade‐off model. In response, this study addresses the question: “To what extent do manufacturing plants view competitive priorities as trade‐offs?” We employ survey data collected from managers and operators in 110 plants that have recently implemented AMT. Our findings suggest that trade‐offs remain. However, perceived differences in competitive priorities are subtle and may vary across levels of the plant hierarchy.     

A FRAMEWORK AND MEASUREMENT INSTRUMENT FOR JUST-IN-TIME MANUFACTURING

While Just-in-Time (JIT) manufacturing has emerged as one of the major tools to enhance manufacturing competitiveness, no attempt has been made to develop a reliable and valid measurement instrument for empirical research in JIT. Without such an instrument, generalization beyond the immediate sample is difficult or misleading. We have proposed a JIT framework and developed a valid and reliable instrument with 16 summated scales for dimensions that capture essential aspects of JIT useful in assessing its impact in manufacturing environments. In addition, we discuss in detail the interactive nature of JIT practice. And, we propose a step-by-step approach to reliability and validity testing. Four JIT practices (equipment layout, pull system support, supplier quality level, and Kanban) are identified as major contributing factors to JIT performance.     

面向制造业务国际化的竞争优先权转移研究

从企业国际化的视角,研究了制造业务国际化过程中的竞争优先权转移问题。在对竞争优先权理论文献研究的基础上,提出研究命题:对于不同制造业务国际化类型的制造企业,其所选择的竞争优先权不尽相同。在IMSS2009的支持下,基于制造业务国际化程度,将企业分为本土、本洲以及全球制造型企业,分析了国际化制造企业的竞争优先权特征以及不同国际化程度的制造企业竞争优先权要素的特征差异。根据研究成果,构建了面向制造业务国际化的竞争优先权转移模型。     

Measurement Equivalence Using Generalizability Theory: An Examination of Manufacturing Flexibility Dimensions

As the field of decision sciences in general and operations management in particular has matured from theory building to theory testing over the past two decades, it has witnessed an explosion in empirical research. Much of this work is anchored in survey‐based methodologies in which data are collected from the field in the form of scale items that are then analyzed to measure latent unobservable constructs. It is important to assess the invariance of scales across groups in order to reach valid, scientifically sound conclusions. Because studies have often been conducted in the field of decision sciences with small sample sizes, it further exacerbates the problem of reaching incorrect conclusions. Generalizability theory can more effectively test for measurement equivalence in the presence of small sample sizes than the confirmatory factor analysis (CFA) tests that have been conventionally used for assessing measurement equivalency across groups. Consequently, we introduce and explain the generalizability theory (G‐theory) in this article to examine measurement equivalence of 24 manufacturing flexibility dimension scales that have been published in prior literature and also compare and contrast G‐theory with CFA. We show that all the manufacturing flexibility scales tested in this study were invariant across the three industry SIC groups from which data were collected. We strongly recommend that G‐theory should always be used for determining measurement equivalence in empirical survey‐based studies. In addition, because using G‐theory alone does not always reveal the complete picture, CFA techniques for establishing measurement equivalence should also be invoked when sample sizes are large enough to do so. Implications of G‐theory for practice and its future use in operations management and decision sciences research are also presented.     

Selecting IT applications in manufacturing: a KBS approach

The use of the right type of Information Technology (IT) applications or manufacturing systems is expected to usher in a competitive advantage. Selection of the right type of IT application is, however, a challenging task. When a company, with a given dominant process structure, emphasizes two or more competitive priorities, such as quality, product flexibility, etc., an unaided manager faces a complex decision problem in choosing from alternative IT applications available in the areas of product design through distribution. In this paper, we present a Knowledge Based System (KBS) that would assist managers with the identification of IT applications that are consistent with both the competitive priorities and the process structure. Validation of the system illustrates that its performance is consistent with the human experts, and it has the potential to facilitate effective and swift decision-making in the selection of appropriate IT applications that best match an organization's manufacturing strategy.     

Enterprise Resource Planning (ERP) Competence Constructs: Two‐Stage Multi‐Item Scale Development and Validation*

This paper defines and operationalizes eight ERP competence constructs. We define ERP competence as a portfolio of managerial, technical and organizational skills and expertise posited as antecedents to improved business performance occurring after an ERP system is operational and functionally stable. To improve responses to changes in markets and products, manufacturers are increasingly adopting ERP systems. However, anecdotal accounts indicate that the realization of ERP's potential benefits is rare. Because of its pervasive influence on manufacturing and business performance, the need for scientifically developed and tested multi‐item scales pertaining to ERP competence is highly relevant to manufacturing strategy research. We follow a two‐stage normative process of scale development. First, we identify a portfolio of eight generic constructs that are hypothesized to be associated with successful ERP adoption. Each construct is then operationalized as a multi‐item measurement scale by applying a manual item sorting technique iteratively to independent panels of expert judges until tentative reliability and validity is established. Second, we further refine and validate the multi‐item scales using survey data from 79 North American manufacturing users of ERP systems.     

An analysis of vendor innovation capability in the contract electronics manufacturing industry

Limited academic research has been given to analysing the innovation capabilities of vendors in outsourcing contracts. This paper seeks to address this gap in the literature by enhancing our understanding of how the innovation capability of vendors is deployed to win, run and renew outsourcing contracts with their customers. Employing the resource-based view as a theoretical basis and undertaking in-depth case study analysis of three vendors in the electronic manufacturing services industry, the research shows that to achieve the outsourcing objectives of winning, running and renewing the contract, vendors can use different configurations of the competitive priorities of cost, quality, delivery and flexibility. The research aggregates the capabilities that influence the innovative capability of a vendor into the innovation-related capabilities (IRCs) of design, new product introduction and manufacturing. Three strategies are identified for vendors on how to deploy these IRCs, and a number of propositions are developed to indicate the suitability of the three deployment strategies for different operational contexts.     

Manufacturing Proactiveness and Performance*

Since Skinner's [40] landmark article depicting the manufacturing function as the “missing link” in corporate strategic processes, a portion of the blame for inferior performance in many firms has been attributed to the subordinate strategic position of manufacturing. It has been argued that part of the solution to misalignments between the capabilities possessed by manufacturing and the requirements dictated by customers is for manufacturing to take a more proactive stance. However, little research has been reported which examines manufacturing proactiveness empirically. In this paper, we address this gap by developing an operational definition of manufacturing proactiveness and testing empirically whether a link exists between proactiveness and performance based on data collected from a sample of manufacturers. Based on the manufacturing strategy literature, we identify two major dimensions of manufacturing proactiveness: (1) the degree of manufacturing's involvement in the strategic processes of the business unit; and (2) the degree of commitment to a long-term program of investments in manufacturing structure and infrastructure aimed at building capabilities in anticipation of their need. We develop reliable scales for measuring each of the dimensions of proactiveness and use the data to provide evidence of a clear link between manufacturing proactiveness and business performance. We show that investments in structural programs coupled with either high levels of manufacturing involvement in strategic processes or planned investments in infrastructural programs correlate with higher than average performance.     

Development and Validation of TQM Implementation Constructs

The contemporary quality management (QM) literature prescribes various quality improvement strategies. However, it lacks scientifically developed and tested constructs that represent an integrative QM philosophy. Moreover, an impact of the prescribed QM strategies on a firm's product quality has not been analyzed. Through a detailed analysis of the literature, this research identifies 12 constructs of integrated QM strategies. Using a survey of 371 manufacturing firms, the constructs are then empirically tested and validated. LISREL 7 is used for this purpose. Finally, a framework to examine the effects of integrated QM strategies on a firm's product quality is suggested. Comparisons between this and two other comprehensive scales of TQM are made.     

制造业国际竞争版图:基于竞争优先权理论的实证研究

从竞争优先权的视角,本文研究了制造企业国际竞争版图。在对竞争优先权理论文献研究的基础上,提出研究命题:由于外部环境的差异,不同地区制造企业的竞争优先权呈现不同的组合特征。在国际制造业战略调查2009的支持下,分析了制造企业竞争优先权的组合特征以及不同地区制造企业竞争优先权的特征差异。数据分析结果显示了四类竞争优先权——全面型、责任型、创新型和看守型。根据研究成果,绘制出制造企业的国际竞争版图,并构建了制造企业国际化竞争决策路径模型。     

STRATEGIC PRODUCTION COMPETENCE: CONVERGENT,DISCRIMINANT, AND PREDICTIVE VALIDITY

A resource-based construct of manufacturing competence, termed strategic production competence, is examined with respect to its convergent, discriminant, and predictive validity. The construct evaluates manufacturing performance across a comprehensive domain of competitive priorities relative to item importance and performance. Data from an earlier study of furniture firms (n = 65) are used for statistical testing. The results establish the convergent and discriminant validity of strategic production competence and show that it is positively related to business performance.     

ASSESSING ENVIRONMENTAL SCANNING AT THE SUBUNIT LEVEL: A MULTITRAIT-MULTIMETHOD ANALYSIS*

Environmental scanning activities of over 400 top management subunits in 108 European manufacturing firms provided the data base for this research. Four traits (constructs) of scanning using three methods (interest, frequency, and time) were examined. A confirmatory factor analysis approach to multitrait-multimethod (MTMM) data was employed. Verification of the reliability as well as convergent and discriminant validity of the scanning scales are reported and discussed. The viability of confirmatory factor analysis in providing a precise analysis of partitioning variance according to trait, method, and error is demonstrated.     

An Empirical Model for Managing Quality in the Electronics Industry

Much of the empirical research in the past two decades has suggested that quality management (QM) is context dependent. This research develops an empirical QM model in a technology‐based sector—electronics manufacturing. Based on quantitative and qualitative investigations of 225 electronics firms in Hong Kong and the Pearl River Delta (PRD) region of China, a path analytic model is developed. The empirical model shows that a typical quality management system (QMS) in the electronics industry is composed of four major modules, namely leadership, cultural elements, operational support systems, and process management. These modules create a series of chain effects on organizational performance, rather than acting as parallel elements with an equal impact. By quantifying their effects on organizational performance and comparing the model to others in the literature, we identify those QM constructs that are context dependent. In electronics manufacturing, process management and customer focus are more important than other elements (e.g., cultural factors) for garnering business results. This study contributes to contingency theory and research by identifying the key constructs and their relationships in a competitive, volatile, and technology‐based industry with complex supply networks.     

Important Strategic and Tactical Manufacturing Issues in the 1990s*

This paper reports the identification and ranking of major manufacturing issues that American manufacturing managers and academics must focus on and resolve in the 1990s to be competitive on a global basis. Vice-presidents of manufacturing from over 75 companies across the United States were asked in a Delphi study to rank the key strategic and tactical issues facing American manufacturing in the next three to five years. Based on three rounds of a Delphi study, quality management, manufacturing strategy, and process technology emerged as the top ranked strategic issues. The top ranked tactical issues were quality control, manufacturing planning and control systems, and work force supervision. These issues were valid across diverse industry groups, since the industrial and educational background of the respondents was shown to have no impact on the final consensus rankings and opinions reported in this paper. Factor analysis of the responses by the panel revealed that certain issues tend to be consistently viewed together, and were interpreted accordingly to provide insights into the ranking of issues. Apart from building a consensus among experts on key manufacturing issues of present and future importance, this study can also be helpful for setting future academic research and pedagogical priorities for the field of production and operations management.     

Decision model for product rollover in manufacturing operations

The purpose of this study is to investigate critical decisions when planning for product rollover at a manufacturing company, and how to organise these decisions. A literature review and a case study are used to develop a decision model. The findings indicate that product rollover can be organised in a five-phase decision model. The research quality is strengthened by a structured literature review, but it can be argued that more empirical research is needed for validation. For researchers, this paper contributes with the identification of critical decisions and a model for product rollover. For practitioners, the study highlights the need to acknowledge the importance of product rollover and its role as a competitive weapon. In earlier studies, product rollover has mainly been investigated from a market perspective, so that this study contributes by investigating the issue from a manufacturing perspective.     

The implications of internationalisation for the management of the vehicle components industry in Britain,Germany, Japan and the U.S.A.

The vehicle components industry, which in recent years has become subject to a more international pattern of competition, provides a good example of how internationalisation forces companies to re-appraise their strategic priorities. The industry's breadth and complexity afford rich international comparisons and suggest conclusions of broader relevance.Thirty British vehicle component manufacturers and thirty from Germany, Japan and the U.S.A. were matched on the basis of six specific components. Field research, entailing discussions with senior executives and factory visits in all four countries, was complemented with desk research analysing the industry more comprehensively.The dramatic decline in company performances, particularly in Britain, reflects over-reliance on higher-level strategies such as diversification, acquisitions, mergers and industrial consolidation, the pursuit of scale economies and the restoration of financial positions through restructuring and retrenchment. Internationalisation calls for competitive strategies that are coherent in the face of powerfully supported international rivals, and generally requires greater market focus. Secondly, basic issues such as manning levels and productivity, quality and flexible manufacturing systems have increased in importance due to radically improved international standards of best practice, established by countries such as Japan.     

The Impact of Mass Customisation on Manufacturing Trade‐offs

Management literature has suggested that the advent of mass customisation marks the end for trade‐offs between customisation and other competitive priorities (Pine et al. 1993; Westbrook and Williamson 1993; Tu et al. 2001). However, evidence supporting this proposition is anecdotal. This paper examines the impact of product customisation on four competitive priorities, drawing upon the results of a recent survey of 102 U.K. manufacturing firms from eight industry sectors. The study indicates significant compatibility between customisation and quality, volume flexibility, delivery reliability and non‐manufacturing costs. On the other hand, trade‐offs remain between customisation and manufacturing costs and delivery lead times. The results contradict the initial proposition that customisation can be “free,” and have important implications for firms embarking upon a mass customisation strategy.     

German,French and British manufacturing strategies compared: A growth towards each other

Manufacturing has gained over the last years in attention as a tool to create competitive advantage. For fou years now a survey has been carried out by a research team at Insead to build a database on the manufacturing strategies as they are defined and implemented by large European companies. In this paper some of the 1987 data are presented, and a comparison of manufacturing strategies of large companies in the three most important European countries is made. Though the most important conclusion is that there are only slight differences between the three countries, one can see some difference in emphasis. The French companies seem to invest heavily to catch up with respect to quality, the German manufacturers invest heavily in technology, and the British seem to pay more attention to the improvement of the labour/management relations. The data on the manufacturing strategies of these groups of companies is also analysed in function of an increased need for flexibility, as it was perceived in previous surveys.