The Role of Culture as Driver of Quality Management and Performance: Infrastructure Versus Core Quality Practices*

Increasingly, scholars and practitioners recognize the importance of understanding organizational culture when implementing operations management practices. This study investigates the relationships among organizational culture, infrastructure and core quality management practices, and manufacturing performance using two alternative models. Understanding these relationships is important because culture can provide insight into the context dependence of quality management practices and shed light on the mixed results of past studies concerning the link between quality management and performance. Analysis of manufacturing plants from six countries indicates that organizational culture has a stronger influence on infrastructure quality management practices than on core quality management practices, regardless of whether the plants are located in Eastern or Western countries. In addition, infrastructure quality management practices have a significant effect on manufacturing performance. These results contribute to the quality management literature by emphasizing the importance of accounting for culture when making decisions to implement quality management practices to achieve a performance advantage. Finally, we also contribute to the literature on the culture–performance linkage by finding support for a direct link between culture and manufacturing performance.     

Improving operational plant performance in international manufacturing networks: the effects of integrative capabilities and plant roles

Abstract

This study adopts the resource-based view to examine how two integrative capabilities of a plant embedded in a manufacturing network enhance operational performance: the capability to connect with other plants in its manufacturing network (a networking capability, NC), and the capability to integrate manufacturing processes with new product development processes (a new product development capability, NPDC). Our model tests the indirect effect of NC on cost, quality, flexibility and delivery through NPDC. Furthermore, we test if the relationship between NC and NPDC depends on the strategic role of the plant. Using survey data from a sample of 521 plants, we confirmed the mediating effect of NPDC. However, the moderation effect was not confirmed. Our findings reveal that plants can deploy NPDC capabilities, fostered by NC, independently from their role in the network. This study contributes to the understanding of plant capabilities and plant roles in manufacturing networks.     

质量管理的核心活动与基础活动——重庆制造业的实证研究

质量管理活动的实证测度是国外运营管理领域的重要内容之一,但国内在此领域的研究却相对少见.本文以重庆市制造业企业为样本,通过两阶段问卷调查收集数据,采用探索性因子分析和结构方程的方法,对我国制造业企业质量管理活动的内容进行了实证研究.结果表明,我国制造业企业中的质量管理活动可以归纳为领导支持、员工参与、员工素质、统计控制、产品设计和流程管理等内容.同时,对质量管理活动的划分为基础活动与核心活动提供了实证支持.研究刻画了质量管理活动的运作机理,指出核心活动与基础活动的有机结合将有助于企业质量管理水平的提升.此外,研究还建议在我国企业质量管理实践中应加强对客户和供应商的重视与支持.     

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.     

The Impact of Complexity on Knowledge Transfer in Manufacturing Networks

Coordinating knowledge transfer within multi‐plant manufacturing networks is a challenging task. Using a computational model, we examine when it is beneficial to create production knowledge within a central unit, the “lead factory,” and transfer it to geographically dispersed plants. We demonstrate that the knowledge transfer generates a trade‐off between a positive cost‐saving effect due to fewer adaptations in each plant, and a negative transfer cost effect due to the costly knowledge transfer itself. The complexity of the production process moderates the performance implications of the knowledge transfer because it determines the relative strength of these two effects. For production processes with low complexity, knowledge transfer can engender superior network performance. Here, an optimal extent of knowledge transfer exists, and thus, a complete knowledge transfer is not performance maximizing. For production processes with medium and high levels of complexity, performance is reduced rather than enhanced through knowledge transfer so that it is optimal not to transfer any knowledge from the lead factory to the plants. While we analyze knowledge transfer within a manufacturing network, our results are transferable to other settings that consist of a knowledge sending and receiving unit.     

Green supply chain performance measurement using the analytic hierarchy process: a comparative analysis of manufacturing organisations

The main purpose of this research is to develop and deploy an analytical framework for measuring the environmental performance of manufacturing supply chains. This work's theoretical bases combine and reconcile three major areas: supply chain management, environmental management and performance measurement. Researchers have suggested many empirical criteria for green supply chain (GSC) performance measurement and proposed both qualitative and quantitative frameworks. However, these are mainly operational in nature and specific to the focal company. This research develops an innovative GSC performance measurement framework by integrating supply chain processes (supplier relationship management, internal supply chain management and customer relationship management) with organisational decision levels (both strategic and operational). Environmental planning, environmental auditing, management commitment, environmental performance, economic performance and operational performance are the key level constructs. The proposed framework is then applied to three selected manufacturing organisations in the UK. Their GSC performance is measured and benchmarked by using the analytic hierarchy process (AHP), a multiple-attribute decision-making technique. The AHP-based framework offers an effective way to measure and benchmark organisations’ GSC performance. This study has both theoretical and practical implications. Theoretically it contributes holistic constructs for designing a GSC and managing it for sustainability; and practically it helps industry practitioners to measure and improve the environmental performance of their supply chain.     

Causal Linkages in Supply Chain Management: An Exploratory Study of North American Manufacturing Firms

In this paper we investigate the key causal linkages in supply chain management. We propose a conceptual framework and test this framework on data from 215 North American manufacturing firms using structural equation modeling techniques. Three major research issues are addressed in this study: Do sourcing decisions affect the degree to which firms achieve manufacturing goals of cost, flexibility, dependability, and quality? Does the degree of manufacturing goal achievement lead to higher customer responsiveness? Does the degree of manufacturing goal achievement lead to higher internal manufacturing performance? The study examines the relationship among sourcing decisions, manufacturing goals, customer responsiveness, and manufacturing performance. The results support the notion that an integrated supply chain involves aligning sourcing decisions to achieve manufacturing goals that are set to respond favorably to the needs of customers.     

Does governance confer organisational resilience? Evidence from UK employee owned businesses

Current economic crisis has highlighted the importance of an organization’s ability to withstand economic shocks. This has rekindled interest in organization resilience on the one hand, and the relationship between alternative governance forms such as employee owned businesses (EOBs) on the other. We explore this relationship using performance data on 204 publicly traded non-employee owned businesses and 49 EOBs prior to the economic downturn (2004–2008), and during the economic downturn (2008–2009). This data is complemented with a survey of resilience related governance and organizational practices in 41 EOBs and 22 non-EOBs. Our results show that: (a) employee ownership that is combined with employee involvement in firm governance is associated with greater stability in business performance over a business cycle; (b) EOBs have longer investment payback horizon when compared to non-EOBs across a number of activities; (c) Top management in EOBs are more likely to seek employee input in strategic decision making; (d) EOBs are more likely to use employee involvement to achieve tighter coupling between feedback from operations and the setting of strategic direction for the firm. These results suggest that employee stock ownership programs alone are not sufficient to develop higher levels of organizational resilience. Managers must combine employee stock ownership with employee involvement in governance if they wish to build up resilience in advance of adverse economic conditions.     

Performance Impacts of Strategy,Information Technology Applications,and Business Process Outsourcing in U.S. Manufacturing Plants

This paper develops a conceptual model to study the role of outsourcing strategies and plant‐level information technology (IT) application infrastructure in the outsourcing of production and support business processes, as well as their subsequent impact on overall plant performance. We validate this model empirically using cross‐sectional survey data from U.S. manufacturing plants. We find that some IT applications are more effective at enabling the outsourcing of business processes than others. For example, the implementation of enterprise management systems is associated with the outsourcing of both production and support processes, whereas operations management systems are not associated with the outsourcing of plant processes. Plants with a low‐cost outsourcing strategy are more likely to outsource support processes than plants with a competency‐focused outsourcing strategy. However, both cost‐ and competency‐based strategies have a positive and similar impact on the outsourcing of production processes. In terms of implications for plant performance, our findings indicate that the outsourcing of production and support processes is associated with higher gross margins. Although plant IT infrastructure is positively associated with favorable on‐time delivery rates, there is no positive association between the incidence of plant outsourcing and on‐time delivery rates. These results have implications for crafting plant‐level outsourcing strategies and for investments in IT systems to facilitate the outsourcing of business processes for enhanced plant performance.     

大型复杂产品制造业集群供应链绩效评价模式研究

本文在已有文献的基础上,结合大型复杂产品制造业集群供应链的特点,提出了用协同性、可靠性、柔性、质量管理和成本控制等5个潜在变量和16个观测变量来评价供应链绩效;在此基础上,用结构方程建模的方法构建了四种评价大型复杂产品制造业集群供应链绩效的可能模式,即单因素一阶模式,潜变量间互不相关的一阶模式,潜变量间存在相关的一阶模式和二阶模式。由于探索性因素分析方法无法建立一致性的绩效评价构面及其体系,因此本文采用验证性因素分析方法从匹配度和稳定性方面来验证和筛选上述四种可能的供应链绩效评价模式。研究结果表明,二阶验证性因素分析模式与样本数据的拟合程度最佳,是有效且可靠的集群供应链绩效评价模式。     

Does Quality Still Pay? A Reexamination of the Relationship Between Effective Quality Management and Firm Performance

Because of the changing competitive environment, quality might have lost some of its luster and emphasis in business. The research question we aim to address in this paper is: Does quality still pay in the new competitive environment? Using replication research, we re‐examine the impact of an effective total quality management (TQM) program on a firm's operating performance in the new competitive environment. We use publicly available data for award‐winning firms and adopt several control‐firm‐selection approaches in our event study. Based on data from more than 500 firms, we find that over a 10‐year period—6 years before to 3 years after winning their first quality award—firms in our sample perform significantly better than control groups in various operating performance measures. Not only do award‐winning firms have better results after receiving awards, they also have superior performance records before the award. Our results suggest that quality is still critical to achieving long‐term competitive advantages, and firms who continuously improve their quality continue to reap rewards by way of sales and financial performances exceeding those of their competitors.     

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.     

Quality and environmental management practices: their linkages with safety performance

There is a widespread acknowledgement that quality and environmental practices are effective means for improving the business performance of firms. However, empirical evidence regarding the relationship between quality and environmental practices and employee safety performance is relatively scarce. In order to fill this gap, we investigate the relationship between quality and environmental practices and safety performance measured by employee accidents at work. Employing a multivariate probit model, we show that the adoption of quality management practices is associated with an increased chance that an employee encounters workplace accidents, whilst environmental practices are associated with a reduction in workplace accidents. However, when distinguishing between workplace accidents that do and do not lead to sick leave, our results reveal that the utilisation of quality practices is not associated to employees’ probability of encountering accidents that lead to sick leave. This suggests that quality practices are only related to benign accidents. Moreover, examining the interrelationships among quality practices, safety performance and quality-related contextual factors, our findings indicate that the implementation of quality practices by the firm that considers quality as very important for its strategy and provides employee’s quality-related training is not associated with safety performance. Therefore, the results suggest that the way a firm implements and uses quality practices is essential for their effect on safety performance.     

AN EXAMINATION OF THE INDIRECT PRODUCTIVITY GAINS FROM QUALITY IMPROVEMENT

Recent theoretical work suggests that quality-improvement activities can yield significant indirect effects through process improvements and reduced factory congestion and confusion, benefits that are overlooked or hidden in most management accounting or cost of quality systems. Using time series data from two consumer durables manufacturing plants, I estimate the indirect productivity gains from quality improvement. The evidence from the plants indicates that the indirect effects from improved quality are at least two to three times the direct benefits attributable to lower scrap, rework, and inventory holding costs. An important implication of these findings is that companies that justify investments and measure performance based only on the direct costs of poor quality will motivate managers to make suboptimal decisions regarding quality-improvement activities.     

Quality Management in Multi‐Level Supply Chains with Outsourced Manufacturing

Outsourcing stretches supply chains longer with added contract manufacturers responsible for the manufacturing of parts and final products. Should a firm change its quality management approach as its supply chain becomes longer with outsourced manufacturing? This paper studies a brand owner's optimal choice between two commonly used quality management approaches: an inspection‐based approach and an external failure‐based approach, in two supply chains – a dyadic supply chain and a multi‐level supply chain where the brand owner outsources manufacturing to an independent contract manufacturer. Our study finds that the brand owner's optimal choice between the two quality management approaches could be opposite in the two supply chains. Specifically, we show that if agency costs exist between the contract manufacturer and the brand owner, the brand owner may prefer an inspection‐based approach in the multi‐level supply chain in contrast to preferring an external failure‐based approach in the dyadic supply chain. In particular, inspections can be effective for the brand owner to limit the manufacturer's profit by excluding defective finished products and components, which in turn reduce agency costs in the multi‐level supply chain. Hence, the efficiency of an inspection‐based approach relative to an external failure‐based approach can be higher in the multi‐level supply chain as compared to the dyadic one. Our findings suggest that firms should adjust to changes in supply chain structures and re‐evaluate the efficiencies of different quality management approaches accordingly.     

A heterarchical generic discrete manufacturing simulation model and its application in a world class manufacturing environment

Current factory design and evaluation is very primitive. Factory components are designed in many cases independently. Product and process design are not well integrated. An encompassing framework is needed for iterating through a series of total factory designs, searching for optimal performance. In addition, a vehicle is needed for predicting the performance of a proposed advanced manufacturing system, so that engineers may have a sound means for evaluating such proposals. A heterarchical discrete manufacturing SIMNET II simulation model (SIMCELLS) was developed as a comprehensive methodology for designing and evaluating discrete manufacturing systems. SIMCELLS allows manufacturing systems engineers to experiment with alternative system structures and control strategies while seeking that combination of design features that will produce the desired overall system performance. The model in combination with a modernization programme is enabling a firm to successfully manufacture and sell trucks meeting international standards. The SIMNET II model     

供应商机会主义行为对信息共享与运营绩效的影响

在交易成本理论基础上,构建供应商机会主义行为、信息共享与运营绩效之间关系的理论模型。以广东省珠三角地区189家制造企业为研究对象,利用结构方程模型对供应商机会主义行为、信息共享与运营绩效的关系进行实证研究。将信息共享划分为信息共享内容和信息共享质量两个维度,将运营绩效划分为速度、服务和财务3个维度。研究结果表明,在供应商机会主义行为与信息共享的关系层面,供应商机会主义行为对信息共享内容和信息共享质量均有显著的负向影响;在信息共享与运营绩效的关系层面,信息共享内容和信息共享质量均对运营绩效有显著的正向影响;而供应商机会主义行为对运营绩效有显著的负向影响。根据上述实证研究结论给出供应链企业和政府的相关管理启示。     

An oracle-based algorithm for robust planning of production routing problems in closed-loop supply chains of beverage glass bottles

The demand for glass bottles is exhibiting an upward trend over time. The manufacturing of glass bottles is costlier in terms of time and resources and is associated with a higher level of heat generation and environmental pollution compared to recycling processes. In response to the aforementioned challenges, companies that use glass bottles need to implement strategies to manage their reverse supply chains in conjunction with their traditional supply chains, as the economic and environmental benefits of returned products are unquestionable. Closed-loop supply chains (CLSCs) integrate forward and reverse flows of products and information. This integration helps companies to have a broader view of the whole chain. Despite these advantages, managing CLSCs can be challenging as they are exposed to many uncertainties regarding supply and demand processes, travel times, and quantity/quality of returned products.In this study, we consider the production planning, inventory management, and vehicle routing decisions of a CLSC of beverage glass bottles. We propose an MILP model and rely on a multi-stage adjustable robust optimization (ARO) formulation to deal with the randomness in both the demand for filled bottles and the requests for pickups of empty bottles. We develop an exact oracle-based algorithm to solve the ARO problem and propose a heuristic search algorithm to reduce the solution time. Our numerical experiments not only show the incompetency of the customary method, namely the affine decision rule approach, but also illustrate how our algorithms can solve the small-size problems and significantly improve the quality of the obtained solution for large problems. Furthermore, our numerical results show that robust plans tend to be sparse, meaning the routes are chosen so that empty bottles are transported to production sites in such a way that fewer new bottles need to be ordered. Thus, robust planning makes the CLSCs more environmentally friendly.     

QoS in the internal supply chain: the next lever of competitive advantage and organisational performance

This article presents a research that examines the relationship of quality of service (QoS) and organisational performance in a manufacturing setting. There are few empirical studies that measure QoS in the manufacturing supply chain. A model linking QoS with organisational performance through intermediate variables of satisfaction, loyalty and competitive advantage is introduced and tested in the internal supply chain of three automotive organisations. The research design for this article includes a combination of literature review, exploratory interviews with scholars and practitioners, and a survey of 156 practitioners in three automotive companies in North India. Structural equation modelling has been used for data analysis. This research comes out with four factor scale for internal service quality and six-factor scale for external service quality. The research revealed that employee-driven QoS is a source of value addition that is positively linked with the organisational performance. This study would be of interest to manufacturing industry practitioners interested in internal and external service quality improvements. Future researchers could validate this scale, and empirically test the proposed model.     

时间窗口约束下基于改进蚁群算法的协同制造调度研究

与传统调度模式不同，协同制造模式下企业之间的调度模式极其复杂。协同企业间的加工工序路线并不固定，且不同类型产品具有不同的加工路线网络。为此本文针对平衡型、瓶颈型、跳跃型、混合型四类具有典型特点的协同制造网络G_p进行分析和设计；考虑制造企业同类产品合并加工策略，构建基于连续加工量的分段生产成本函数；通过设计合理的订单最早交货时间和最晚交货时间，对订单交货进行时间窗口约束，并在此基础上构建了由制造商生产成本W_c^m、订单等待W_s^k（Q_k， T'_k）和提前完工库存成本W_s^k（Q_k， T″_k）、延期惩罚成本构成W_l^k（Q_k， T'″_k）的目标函数。为求解该模型，创新性将蒙特卡洛思想引入蚁群算法，提高蚂蚁选择合理性，避免局部最优；同时，采用移动窗口[min， max]奖励机制，并且对信息素奖励乘以平衡系数k（N）提高奖励可信度，加快搜索速度并提高求解性能。仿真结果表明，本文构建调度模型合理，可以获得优化的调度结果；同时，本文提出的蚁群改进寻优算法具有良好的求解速度和收敛性，算法具有较好的稳定性。