The effects of human resource systems on operational performance in mass customisation manufacturing environments

This study empirically examines the impact of two human resource management (HRM) systems on operational performance in two distinct mass customisation manufacturing (MCM) environments. Using the survey data collected electronically from 148 mass customisation manufacturers in the USA, moderated hierarchical multiple regression was employed to test the research hypotheses. Results suggest that operational performance significantly increases when a bundle of complementary basic HRM practices are integrated in MCM contexts that emphasise module and process standardisation. This finding indicates that these types of mass customisation manufacturers are capitalising on the opportunity to improve operational performance by strategically combining several different, but supportive, traditional HRM practices with a finite MCM system.     

Lampshade Game for lean manufacturing

The purpose of this article is to introduce a new simulation game named the ‘Lampshade Game’ that can be helpful in educating students and industry professionals on lean manufacturing principles. The Lampshade Game is an active learning tool that is capable of demonstrating the advantages and disadvantages of some of the key principles of lean manufacturing (such as quality focus, pull system, flexible manufacturing and visual organisation) in comparison to craft and mass manufacturing by manually simulating the production of lampshades for each of the process types. The game enables the comparison of these three manufacturing methods using different operational and financial metrics such as inventory levels, manufacturing cycle time, customer fill rate, production yield and cost and profit. This article describes the game, its objectives, and shares experiences from several classroom implementations including an analysis of pre- and post-surveys.     

Lean practices and their effect on performance: a literature review

This paper introduces a literature review of 83 studies dealing with the degree of adoption of lean manufacturing practices around the world, and the links between those practices and organisation performance. The results of this study revealed that lean practices application still occurs in a fragmented way, disregarding the systemic linkage that is essential to lean manufacturing. Forty-one articles have suggested a positive effect of lean practices in at least one operational, financial and/or environmental performance metric. Nevertheless, five studies indicated that some lean practices had a negative effect on operational or financial performance. High demand variability, a perceived result of long-term lean manufacturing implementation, a country/company’s organisational culture and the difficulty of traditional costing production systems to measure and compare investments and economic gains from adopting lean manufacturing over time are some of the reasons to explain that negative effect of lean practice on performance.     

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.     

An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the U.K.

Abstract

Competitive landscape, informed consumers and stringent regulations have forced many manufacturing small- and medium-sized enterprises (SMEs) to focus on operational efficiency along with sustainability issues in recent years. While many manufacturing organisations have been taking lean initiatives for the past few years for operational excellence, an impulsive rush to adopt lean without a strategic deployment vision has led to scattered implementation of lean tools and projects without desired success. Many researchers and practitioners prescribe value stream mapping as a foundation for lean transformation initiatives; however, little empirical work is available on the symbiosis of lean and green paradigms to reap maximum benefits. This research, through a systematic methodology and a novel tool called Green Integrated Value Stream Mapping (GIVSM), integrates both paradigms in a case study on a U.K. packaging-manufacturing SME. Applying the GIVSM demonstrates that simultaneous deployment of lean and green paradigms have synergistic effect for improving both operational efficiency and environmental performance. In addition, continuous improvement framework with sustainable procurement is proposed to overcome the lean-green misalignments. This study also provides a guiding reference for practitioners to undertake similar improvement projects and identifies opportunities to expand this academic research on integrated lean-green approach into other industry sectors.     

Location of Inventories in an MRP Environment

Previous research on MRP systems has rarely considered at what level in a modular sub-assembly product structure to hold inventories. Based on a simulation study of an MRP environment, we show that the correct decision concerning where to hold inventory depends on the variance in end-item demand, the amount of inventory investment, and concomitantly, the desired level of customer service. In particular, for small investment in inventories and moderate end-item demand variance, it is equally effective to hold inventories at the subassembly level or the end-item level. But when end-item demand variance is high, subassembly level inventories are better. As inventory investment grows, however, it is best to use a diversified approach of holding both subassembly and end-item inventories, irrespective of end-item demand variance. The robustness of these conclusions is validated by simulating a hypothetical firm that also uses safety time to hedge against uncertainties.     

Order Promising and the Master Production Schedule*

Previous research on material requirements planning (MRP) systems has rarely considered the impact of the master production scheduling method used to promise customer orders and to allocate production capacity. Based on a simulation study of an MRP environment, we show that the correct selection of a master production schedule (MPS) method depends on the variance of end-item demand. In addition, we find evidence that the effectiveness of a particular MPS method can be enhanced by holding buffer inventory at the same level in the product structure as in the MPS.     

Satisfying and Retaining Customers through Independent Service Representatives

The degree of leverage possessed by manufacturers who outsource their customer service function to channel partners over customer satisfaction and loyalty is assessed empirically. Data provided by independent service representatives are linked with data from their customers. Results indicate that a manufacturer's support of its representatives increases their job satisfaction which, in turn, is indirectly linked to the customer satisfaction through shared perceptions of service performance and quality. However, the strength of the effects is modest, suggesting that manufacturers may need to consider direct customer contact strategies or contractual means of assuring customer satisfaction when independent service representatives “own the customer.” Conceptually, the hypothesized shared mindset model is tested against the competing affect transfer model, resulting in support for the former. Job satisfaction moderates the degree of agreement between representatives' and customers' perceptions of service performance and quality such that greater agreement occurs when job satisfaction is high.     

AN APPLICATION OF MATERIAL REQUIREMENTS PLANNING TO HIGHER EDUCATION

Material requirements planning (MRP), a comprehensive planning and control technique based upon the dependent demand principle, enables manufacturing organizations to provide better customer service, reduce inventory investment, and increase resource utilization. This paper extends the dependent demand principle to the service sector and thus provides the basis for applying MRP to higher education. In the short run, administrators can schedule the necessary number of required courses and load each course based on student priorities to provide increased customer (i.e., student) service and faculty utilization. In the long run, course enrollment forecasts can be utilized by administrators to plan and control changes in faculty resources across departments and schools.     

MRP system performance under lumpy demand environments

Material requirements planning (MRP) systems are deemed to deal with master schedules with lumpy demand patterns better than any other production scheduling system. Past studies have advocated important advantages of using MRP systems. The objective of this paper is to look into the impact of patterns of demand lumpiness on the performance of MRP systems by a simulation study. Results show that there is an important threshold point in terms of degree of lumpiness at which MRP system performance starts to deteriorate in the operating conditions considered. If master production schedules (MPS) can be controlled by manufacturers, MRP users should exercise caution to introduce demand lumpiness in MPS to improve system performance. If not, MRP users should then examine the given lumpiness and choose an appropriate lot-sizing rule that has been shown to take advantage of the effect of demand lumpiness.     

A decision support system for optimising the order fulfilment process

Many authors have highlighted gaps at the interfaces between supply chains (SCs) and demand chains. Generally, the latter tends primarily to be ‘agile’ by maximising effectiveness and responsiveness while the former tends to be ‘lean’ by maximising efficiency. When, in the SC, disruptions (that lead to stock-out situations) occur after customer orders have been accepted, managers are faced with the problem of maximising customer satisfaction while taking into consideration the conflicting objectives of the supply and demand sides of the order fulfilment process. This article proposes a cross-functional multi-criteria decision-making (advanced available-to-promise) tool that provides different strategic options from which a solution can be chosen. It also proposes a performance measurement system to support the decision-making and improvement process. The results of some experimental tests show that the model enables to make strategic decisions on the degree of flexibility required to achieve the desired level of customer service.     

The complementarity of internal integration and product modularity: An empirical study of their interaction effect on competitive capabilities

Modular product design and internal integration are commonly adopted by manufacturers to improve operational performance. A number of studies argue that the adoption of product modularity significantly alters organization design, which affects the impact of internal integration on competitive capabilities. This paper thus aims to empirically explore the individual effects as well as interaction effects of product modularity and internal integration on competitive capabilities. The competitive capabilities studied in this paper include product innovativeness, low price, product quality, delivery, flexibility and customer services. After analysing the data from 251 Hong Kong manufacturers through moderated multiple regression analysis, the study found that better internal integration can significantly improve product innovativeness, product quality, delivery, flexibility and customer services, while a high level of product modularity enhances product innovativeness, flexibility and customer services. More importantly, the study shows that internal integration and product modularity can interact to improve product innovativeness and product quality. These results enhance our understanding of the interaction of product design and organizational coordination.     

The Effects of Strategic and Structural Supply Chain Orientation on Operational and Customer‐Focused Performance

Supply chain orientation (SCO), or the implementation of a supply chain management philosophy, consists of two distinct, yet interdependent elements, namely strategic SCO and structural SCO. Strategic SCO involves integrating an SCM philosophy into the firm's strategy development, while structural SCO encompasses operational‐level behaviors and actions that reflect such a philosophy. This study extends the research on SCO by developing hypotheses on the contingent effects of strategic SCO and structural SCO on a firm's operational and customer‐focused performance. Drawing on the strategy‐structure‐performance framework, the study proposes that strategic SCO and structural SCO positively affect different dimensions of performance and that structural SCO plays a mediating role in the relationship between strategic SCO and performance. These relationships are tested using primary survey data and archival data from 183 manufacturers in the Midwestern US. Results confirm that strategic SCO is associated with both operational performance and customer‐focused performance, but structural SCO is only related to operational performance. Structural SCO acts as a mediator in linking strategic SCO with operational performance and customer‐focused performance and mediation effects are strengthened at higher levels of environmental dynamism.     

Value–value load diagram: a graphical tool for lean–green performance assessment

Integrated assessment of operational and environmental performance of the production system requires mapping of all the processes and activities in the form of their resource utilisation efficiency. Prior research indicates that most lean assessment tools and techniques have studied operational dimensions ignoring environmental aspect as a part of the assessment tool. Moreover, movement towards the greener production system has become a key strategic consideration for organisations to maintain a competitive edge and to remain as market winners. Continuous assessment in both, lean and green, dimensions is crucial in improving the overall performance through efficient utilisation of the available resources. In lean environment, value stream mapping (VSM) allows assessment of operational performance through identification of non-value adding activities in time units but fails to integrate inefficiencies related to material and energy utilisation. The tool-like material flow cost accounting (MFCA) is able to assess the environmental performance through physical and monetary evaluation of material flow within the production system. This paper presents, a novel tool, value–value load diagram (VVLD), for modelling and evaluating the operational (lean) and environmental (green) performance of the production system. VVLD graphically represents resource consumption, value addition and performance improvement opportunities within the production system by integrating VSM, MFCA and pinch analysis methodology. VVLD permits evaluation of the lean–green performance in terms of the eco-leanness index and also exposes the improvement opportunities by pinch point location. Some common generic scenarios for improvement in the eco-leanness index are demonstrated using VVLD. Application of VVLD along with the developed computer-based support system (CBSS) is demonstrated for a manufacturing SME in India, allowing the managers to evaluate and tune their processes for improved resource utilisation efficiency.     

Supply Chain Strategy,Product Characteristics,and Performance Impact: Evidence from Chinese Manufacturers*

Supply chain management has become one of the most popular approaches to enhance the global competitiveness of business corporations today. Firms must have clear strategic thinking in order to effectively organize such complicated activities, resources, communications, and processes. An emerging body of literature offers a framework that identifies three kinds of supply chain strategies: lean strategy, agile strategy, and lean/agile strategy based on in‐depth case studies. Extant research also suggests that supply chain strategies must be matched with product characteristics in order for firms to achieve better performance. This article investigates supply chain strategies and empirically tests the supply chain strategy model that posits lean, agile, and lean/agile approaches using data collected from 604 manufacturing firms in China. Cluster analyses of the data indicate that Chinese firms are adopting a variation of lean, agile, and lean/agile supply chain strategies identified in the western literature. However, the data reveal that some firms have a traditional strategy that does not emphasize either lean or agile principles. These firms perform worse than firms that have a strategy focused on lean, agile, or lean/agile supply chain. The strategies are examined with respect to product characteristics and financial and operational performance. The article makes significant contributions to the supply chain management literature by examining the supply chain strategies used by Chinese firms. In addition, this work empirically tests the applicability of supply chain strategy models that have not been rigorously tested empirically or in the fast‐growing Chinese economy.     

The impact of lean practices on operational performance – an empirical investigation of Indian process industries

In deciding to adopt lean manufacturing, it is imperative to investigate where and how lean practices are most needed to influence manufacturing and business performance. Such an investigation becomes indispensable when lean thinking is to be considered in a production arrangement different to the conventional, repetitive, high-volume, stable-demand and discrete-manufacturing environment. This study provides explanations of how performance is improved through the adoption of lean practices in process industries. This is a relatively under-researched area compared to the performance effects associated with the introduction and implementation of lean principles in traditional, discrete manufacturing. Based on a survey of Indian process industries, this study attempts to develop an empirical relationship between lean practices and performance improvement through the use of multivariate statistical analysis. The findings have led to the conclusion that lean practices are positively associated with timely deliveries, productivity, first-pass yield, elimination of waste, reduction in inventory, reduction in costs, reduction in defects and improved demand management. However, within a process-industry context, lean practices related to pull production were found to have a marginal impact on performance improvement. A detailed discussion of the findings along with their theoretical and managerial implications is provided in the paper.     

Benefits of adopting lean production on green performance of SMEs: a case study

Abstract

Small- and medium-sized enterprises (SMEs) are widely recommended to strive, not only for their performance in operational side, but they need to integrate the environmental dimension. To do that, the literature widely indicates a positive impact of lean practices on green performance. However, very few studies have been carried out in SMEs context. In this view, this paper aims at providing through a practical case study of lean implementation in a real-life small manufacturing company, the information to confirm this synergy between lean and green performance. To achieve this aim, a proposed framework of lean and green integration has been implemented in a SME producing different types of pumps. The results achieved shows that there is a strong correlation between operational metrics improvement and green metrics improvement. Moreover, the benefits of lean practices such as 5S, Kanban, SMED, AM, cellular manufacturing and quality control on green performance are widely demonstrated. Future work could study other processes and explore other case-specific supporting tools and techniques.     

Planning and Control in Multi-Cell Manufacturing

This research compares Material Requirements Planning (MRP), Kanban, and Period Batch Control (PBC) as alternative approaches to the planning and control of multi-cell manufacturing involving flow cells and assembly. Since previous research on performance of these systems in cellular manufacturing has been primarily conceptual, the experiments reported here provide new insights into their comparative performance. The results show that the production environment is a major factor in system choice. Three operating factors—Master Production Schedule (MPS) volume variation, MPS mix variation, and setup time/lot size—clearly affect system choice. All systems performed well under Justin-Time (JIT) conditions; there was no advantage to Kanban. Under the mixed conditions of high MPS variation, but small setup time/lot sizes, PBC produced superior performance compared to Kanban and MRP. Under non-JIT conditions, MRP was seen as clearly more effective. Finally, the results indicate that when conditions permit very small lot sizes relative to requirements, Kanban may perform best, even when MPS variation is high.     

Reference model for implementing an MRP system in a highly diverse component and seasonal lean production environment

Companies are currently choosing to integrate logics and systems to achieve better solutions. These combinations also include companies striving to join the logic of material requirement planning (MRP) system with the systems of lean production. The purpose of this article was to design an MRP as part of the implementation of an enterprise resource planning (ERP) in a company that produces agricultural implements, which has used the lean production system since 1998. This proposal is based on the innovation theory, theory networks, lean production systems, ERP systems and the hybrid production systems, which use both components and MRP systems, as concepts of lean production systems. The analytical approach of innovation networks enables verification of the links and relationships among the companies and departments of the same corporation. The analysis begins with the MRP implementation project carried out in a Brazilian metallurgical company and follows through the operationalisation of the MRP project, until its production stabilisation. The main point is that the MRP system should help the company's operations with regard to its effective agility to respond in time to demand fluctuations, facilitating the creation process and controlling the branch offices in other countries that use components produced in the matrix, hence ensuring more accurate estimates of stockpiles. Consequently, it presents the enterprise knowledge development organisational modelling methodology in order to represent further models (goals, actors and resources, business rules, business process and concepts) that should be included in this MRP implementation process for the new configuration of the production system.     

Editorial Another milestone

A Master Production Scheduling Decision Support System within a multi-product medical supplies market has the dual task of providing good customer service levels while maintaining minimum reasonable levels of finished goods stock in the face of considerable internal manufacturing lead time and customer demand uncertainty. This paper examines the critical design parameters within an adaptive model highlighting how the total system orders in the internal pipeline are utilized in the decision-making process for assessing how much to load the internal manufacturing pipeline. Two different methods for tracking manufacturing lead times within the adaptive loop are also considered. Classical control concepts are applied within the Decision Support System (DSS) to avoid any long-term drift in finished stocks. Finally scenario analysis is performed via simulation for a set of design parameters and a range of stimuli typical of company operating situations. An effective decision support system design in terms of architecture and parameter settings is recommended based upon the ability of the model to maintain high customer service levels. The DSS readily interfaces between marketing and production functions to enhance company competitive advantage across a wide range of products.