Manufacturing flexibility and performance: bridging the gap between theory and practice

How firms scan and interpret their environments has implications for the flexibility strategy that they choose, as well as for the performance of that strategy. We extend Daft and Weick's (Acad Manage Rev 9(2):284-295, 1984) model of firms as interpretation systems into a theoretical model of flexibility performance through extended iterations between observations of a failed flexibility initiative and relevant literature. We test the model using well-known teaching cases. We argue that the use of an iterative process that involves cases and theory both stimulates creativity in integrating theory and lays an initial foundation for evidence-based practic

Manufacturing Flexibility and Performance: Bridging the Gap between Theory and Practice

How firms scan and interpret their environments has implications for the flexibility strategy that they choose, as well as for the performance of that strategy. We extend Daft and Weick's (Acad Manage Rev 9(2):284-295, 1984) model of firms as interpretation systems into a theoretical model of flexibility performance through extended iterations between observations of a failed flexibility initiative and relevant literature. We test the model using well-known teaching cases. We argue that the use of an iterative process that involves cases and theory both stimulates creativity in integrating theory and lays an initial foundation for evidence-based practice

Economies of Extremes: Lessons from Venture-Capital Decision Making

An organization's ability to exploit extreme events such as exceptional opportunities depends on its capacity strategy. The venture capital industry illustrates the interplay of expensive capacity and negative externalities from high utilization. The cost of adding a venture capitalist provides a strong incentive to run lean, but such leanness may make it impossible to evaluate all interesting investment opportunities. Using concepts from extreme-value theory, we analyze the trade-off between the costs and benefits arising from an increase in the number of evaluated deals. We ground our analysis in 11 years of archival data from a venture capital firm, representing 3631 deals, the decisions made, the reasons for those decisions, and the decision lead times. The firm identified 20% of arriving deals as worth evaluating during the screening process, but was not able to evaluate approximately 9% of those interesting deals due to a lack of capacity. We show that the value of increasing the number of deals evaluated increases with the tail weight of the distribution of deal values. When the right tail is light, increasing the number of deals evaluated may provide too modest a benefit to justify the cost. When, however, the right tail is heavy, the value of increasing the number of deals is likely to more than compensate for the cost of capacity. Our results provide new insight into the relative value of a chase capacity strategy that emphasizes responsiveness versus a high-utilization heuristic that emphasizes productivity. Our approach can be applied to other search operations such as personnel selection, quality circles seeking to identify root causes, and making employee capacity available for innovation

Factors influencing employee perceptions in lean transformations

The purpose of the study was to investigate employee perceptions during a lean transformation1. The combination of case study and survey methodologies was used to define elements influencing the perceived lean success of shop floor employees. According to our findings, belief, commitment, work method and communication all have a considerable direct impact on workers’ perceptions of lean success. However, their effects are very different based on the scope and focus of changes that is influenced by process characteristics. Perceptions regarding successful lean transformation during a moderate reorganisation of the company’s welding plant, where mainly males work, are affected only by commitment and work method, whereas the deep reorganisation of the sewing plant (populated by female employees) is only influenced by belief and communication

Simulation in manufacturing and business: A review

Copyright @ 2009 Elsevier B.V.This paper reports the results of a review of simulation applications published within peer-reviewed literature between 1997 and 2006 to provide an up-to-date picture of the role of simulation techniques within manufacturing and business. The review is characterised by three factors: wide coverage, broad scope of the simulation techniques, and a focus on real-world applications. A structured methodology was followed to narrow down the search from around 20,000 papers to 281. Results include interesting trends and patterns. For instance, although discrete event simulation is the most popular technique, it has lower stakeholder engagement than other techniques, such as system dynamics or gaming. This is highly correlated with modelling lead time and purpose. Considering application areas, modelling is mostly used in scheduling. Finally, this review shows an increasing interest in hybrid modelling as an approach to cope with complex enterprise-wide systems

Inventory control with seasonality of lead times

The practical challenges posed by the seasonality of lead times have largely been ignored within the inventory control literature. The length of the seasons, as well as the length of the lead times during a season, may demonstrate cyclical patterns over time. This study examines whether inventory control policies that anticipate seasonal lead-time patterns can reduce costs. We design a framework for characterizing different seasonal lead-time inventory problems. Subsequently, we examine the effect of deterministic and stochastic seasonal lead times within periodic review inventory control systems. We conduct a base case analysis of a deterministic system, enabling two established and alternating lead-time lengths that remain valid through known intervals. We identify essential building blocks for developing solutions to seasonal lead-time problems. Lastly, we perform numerical experiments to evaluate the cost benefits of implementing an inventory control policy that incorporates seasonal lead-time lengths. The findings of the study indicate the potential for cost improvements. By incorporating seasonality in length of seasons and length of lead times within the season into the control models, inventory controllers can make more informed decisions when ordering their raw materials. They need smaller buffers against lead-time variations due to the cyclical nature of seasonality. Reductions in costs in our experiments range on average between 18.9 and 26.4% (depending on safety time and the probability of the occurrence of stock out). Therefore, inventory control methods that incorporate seasonality instead of applying large safety stock or safety time buffers can lead to substantial cost reductions

Nurturing Business Ecosystems for Growth in a Foreign Market: Incubating, Identifying and Integrating Stakeholders

This paper explores the process of nurturing a business ecosystem to facilitate corporate growth in an unfamiliar foreign market with high product uncertainty and no network resources. The authors conducted a qualitative, longitudinal study by examining a successful business case — ARM (a leader in microprocessor intellectual property) — to demonstrate how firms nurture their business ecosystems to develop in the Chinese market and to stimulate demand even with- out the advantages of resources and stabilized products. Based on the road map method, this paper develops a framework of creating a business ecosystem in three sequential stages namely, incubating complementary partners, identifying leader partners, and integrating ecosystem part- ners. The findings enrich classic international business and demand chain theories by highlighting different roles stakeholders adopt to cope with uncertain products in a foreign market. In practical terms, these findings also provide Mode 2 knowledge with application context (Gibbons et al., 1997) on entering new markets by building up an ecosystem

A manufacturer-buyers integrated inventory model with generic distribution of lead times to deliver equal and/or unequal batch sizes

Although lead time variation is common in practice, integrated single-manufacturer multi-buyer model considering this factor is unavailable in the extant literature. This article considers generic distribution of lead times of delivering equal and/or unequal batch (sub-lot) sizes of a lot in developing a synchronised integrated single-manufacturer multi-buyer model. The batch sizes are assumed to be in geometric series. The variables considered in the model are the smallest batch size, total number of batches and number of unequal batch sizes delivered from the manufacturer to buyers. The smallest batch sizes delivered to the buyers are bounded below by 1 and above by the capacity of the transport vehicle. The minimal total cost solution technique to the model is derived by the method of differentiation. Significant minimal total cost reductions by the synchronised flow is illustrated through solutions to some numerical example problems. Sensitivity analyses on increasing costs of transportation, shortage, inventory and increasing mean lead times upon the optimal solution have been performed