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Lot streaming is the process of splitting a production lot into sublots and then scheduling the sublots in overlapping fashion on the machines in order to improve the performance of the production system. Implementation of this concept arises in several batch production environments. These include, among others, printed circuit board assembly and semiconductor fabrication. There are several limitations in the lot-streaming models available in the literature which affect their usefulness in reality. In this paper, we consider the single batch, flow shop, lot-streaming problem but relax several of these limitations. The main contribution of this paper is to provide the production manager with a way of splitting a lot in order to optimize performance under various measures of performance and setup time considerations. In addition, the insight of the proposed procedure can be used to tackle more general versions of the problem considered. [ABSTRACT FROM AUTHOR]

This paper investigates the interaction between the economics of production and imperfections in the production process. Specifically, this paper is the first to devise a model in an attempt to provide managers with guidelines to choose the appropriate production run times to buffer against both the production of defective items and stoppages occurring due to machine breakdowns. In addition to providing several structural properties of the model, we show that a manager will always incur a cost penalty when (s)he uses the results of two oft-cited models—the EMQ (Economic Order/Manufacturing Quantity) and the NR-E (No-Resumption, Exponential machine breakdown)—to determine production run times. [ABSTRACT FROM AUTHOR]

A common manufacturing environment in many industries (such as the glass, steel, paper, costume jewelry, and textile industries) is a hybrid flow shop. This system has continuous-process machinery in the first stage of manufacturing and repetitive-batch equipment in the second. Little research has investigated this type of system. Scheduling managers of hybrid flow shops tend either to use existing job-shop rules or to devise their own rules. These approaches often are less than adequate for efficient scheduling. In this paper we extend the rule presented by Narasimhan and Panwalkar to include a general class of hybrid flow shops. This extension, called the generalized cumulative minimum-deviation (GCMD) rule, is compared under various operating conditions to three other sequencing rules: shortest processing time, longest processing time, and minimum deviation. The operating conditions are determined by the number of machines at both stages. The results of 7200 simulation runs demonstrate that the GCMD rule is better than the other rules in minimizing each of five chosen criteria. Thus, the GCMD rule can help managers to schedule hybrid flow shops efficiently to achieve various corporate objectives. [ABSTRACT FROM AUTHOR]

This paper reexamines the idea of developing an index of manufacturing fit with market requirements. Bozarth and Berry's (1997) recent work provides a starting point. Several conceptual and methodological issues relating to the Bozarth and Berry approach are raised. It is argued that the indifference profile concept suggested by the authors bears reexamination. [ABSTRACT FROM AUTHOR]

This paper examines the use of costs and cost functions to model lot-sizing decisions in batch manufacturing. The cost functions used to model a wide variety of manufacturing systems are typically derived from average cost models of unconstrained inventory problems. The use of setups and average inventories as the basis for modeling the economics of a typical batch manufacturing cell is shown to be inadequate. An alternative physical model that focuses on lead times provides a model that more closely represents the underlying value of such a cell. [ABSTRACT FROM AUTHOR]

In a recent paper, McKnew, Saydam, and Coleman [3] presented a novel zero-one integer programming formulation of the multilevel dynamic, deterministic lot-sizing problem in assembly systems. They stated that "the relaxed linear programming solution to this formulation will always be integer" [3,p. 280] since the constraint matrix is totally unimodular. In this note, we point out that the constraint matrix is not totally unimodular and therefore the authors' claim that a linear relaxation of the zero-one integer formulation always yields an integer solution is not true.

The production line approach has been beneficially used in manufacturing companies to yield consistent-quality standard products at relatively low cost. For this reason, service firms have also employed this approach, which embodies a division of labor, sequential flow processes, and standardization of services. Today's customers, however, are demanding customized services and shorter cycle times-outcomes that the production line approach finds difficult to achieve. An alternative process design proposed for information intensive services is the emerging "case manager" approach, in which all the steps required to deliver a service are performed by a single information technology enabled individual. This paper uses queuing theory to compare the waiting time performance of the production line and the case manager approaches. This comparison shows that when the number of process steps under the production line approach is relatively large, the relative efficiency of the case manager is sufficiently high, system utilization rate is moderate, and the size of staff downsizing is small, the case manager approach is preferred. Critical issues for the design of enabling information technology are then discussed. The paper concludes with suggestions for future research on the case manager approach. [ABSTRACT FROM AUTHOR]

A large number of techniques for solving the cell formation problem has emerged in recent years. However, little effort has been spent on determining the procedures' relative performance. This paper identifies four problem areas for which important decisions must be made in connection with a comparative study: asymmetry among procedures with respect to input data, sensitivity to input data, ability of cell formation techniques to generate different solutions, and criteria for acceptable cell performance. Relying on a new taxonomy that categorizes cell formation techniques based on required input data, and a new approach to describing and manipulating shop data, this paper illustrates how choices within the four areas above can be resolved within the context of a comparative study. The experiments uncover fundamental relations between cell formation techniques, the types of input data they use, the characteristics of the data that drive the models, and the resulting performance. [ABSTRACT FROM AUTHOR]

The design of a manufacturing strategy incorporates the decision of whether to focus or vertically integrate, or adopt a policy somewhere between the two extremes. Unfortunately, the literature contains few models that aid a manager in this decision process. In this paper we design a model to evaluate and compare various strategic alternatives along the focused factory-vertical integration continuum. By defining a point along this continuum as the percent of components manufactured internally that are needed to make one finished item (where 0 indicates complete focus and one manufacturing step, and 1 indicates full integration and 100 percent internal manufacturing) we are able to delineate the effects of the alternative decision strategies on flexibility and the firm's cash flow. The capital asset pricing model is invoked to assess the impact on the firm's risk and value. [ABSTRACT FROM AUTHOR]

Use of the net realizable value approach for joint manufacturing cost allocations requires knowledge of selling prices of joint products. However, joint product selling prices themselves are functions of the allocated costs under a cost-plus pricing policy. In this case, it is necessary to determine joint cost allocations and joint product prices simultaneously. This paper applies a nonlinear programming (NLP) approach to simultaneously determine the optimal joint production decision, joint product cost-plus prices, and joint cost allocations using the net realizable value method. The NLP solution provides not only the optimal joint production and pricing decisions, but also the necessary conditions for such optimal decisions. [ABSTRACT FROM AUTHOR]

In uncertain environments, the master production schedule (MPS) is usually developed using a rolling schedule. When utilizing a rolling schedule, the MPS is replanned periodically and a portion of the MPS is frozen in each planning cycle. The cost performance of a rolling schedule depends on three decisions: the choice of the replanning interval (R), which determines how often the MPS should be replanned; the choice of the frozen interval (F), which determines how many periods the MPS should be frozen in each planning cycle; and the choice of the forecast window (T), which is the time interval over which the MPS is determined using newly updated forecast data. This paper uses an analytical approach to study the master production scheduling process in uncertain environments without capacity constraints, where the MPS is developed using a rolling schedule. It focuses on the choices of F, R, and T for the MPS. A conceptual framework that includes all important MPS time intervals is described. The effects of F, R, and T on system costs, which include the forecast error, MPS change, setup, and inventory holding costs, are also explored. Finally, a mathematical model for the MPS is presented. This model approximates the average system cost as a function of F, R, T, and several environmental factors. It can be used to estimate the associated system costs for any combination of F, R, and T. [ABSTRACT FROM AUTHOR]

The product structure is a key input to a material requirements planning system. Yet, the effect of alternate product structure designs on system performance is not well understood. Analytical measures are needed to accurately relate product-structure characteristics to total cost and delivery performance. A new analytical measure of product structure called the degree of commonality index is defined in this paper. The degree of commonality index can be applied to single end items, product families, entire product lines, or to any level of product structure. This study suggests that component part commonality, as measured by the degree of commonality index, has a significant effect on system performance. For example, company standardization programs that increase the degree of component part commonality result in manufacturing cost reductions. The degree of commonality index provides a way to directly relate the degree of component part commonality to various dependent variables such as total cost, work center load, and delivery performance. [ABSTRACT FROM AUTHOR]

This paper considers the application of cellular manufacturing (CM) to batch production by exploring the shop floor performance trade-offs associated with shops employing different levels of CM. The literature has alluded to a continuum that exists between the purely departmentalized job shop and the completely cellular shop. However, the vast majority of CM research exists at the extremes of this continuum. Here, we intend to probe performance relationships by comparing shops that exist at different stages of CM adoption. Specifically, we begin with a hypothetical departmentalized shop found in the CM literature, and in a stepwise fashion, form independent cells. At each stage, flow time and tardiness performance is recorded. Modeling results indicate that, depending on shop conditions and managerial objectives, superior shop performance may be recorded by the job shop, the cell shop, or by one of the shops between these extreme points. In fact, under certain conditions, shops that contain partially formed cells perform better than shops that use completely formed cells. Additional results demonstrate that in order to achieve excellent performance, managers investigating specific layouts need to pay especially close attention to changes in machine utilization as machine groups are partitioned into cells. [ABSTRACT FROM AUTHOR]

Although order and labor dispatching in the job shop manufacturing setting have been investigated extensively over the last three decades, its representation of actual processes found in practice today is limited due to the move to cellular manufacturing (CM). Manufacturing cells have become an important approach to batch manufacturing in the last two decades, and their layout structure provides a dominant flow structure for the part routings. The flow shop nature of manufacturing cells adds a simplifying structure to the problem of planning worker assignments and order releases, which makes it more amenable to the use of optimization techniques. In this paper we exploit this characteristic and present two mathematical modeling approaches for making order dispatching and labor assignment/reassignment decisions in two different CM settings. The two formulations are evaluated in a dynamic simulation setting and compared to a heuristic procedure using tardiness as the primary performance measure. The formulations are superior to the heuristic approach and can be incorporated into detail scheduling systems that are being implemented by corporations employing enterprise resource planning (ERP) systems today. [ABSTRACT FROM AUTHOR]

In this paper the impacts of two types of repetitive scheduling systems on the makespan in a two-stage hybrid flow shop, which consists of one machine in the first stage and multiple process lines in the second stage, are compared. First, we analyzed, through a simulation, how the makespan is affected by the setup frequency and sequencing rules for products under two types of scheduling systems: One is repetitive scheduling with only one batch per product family per scheduling cycle (basic cyclic scheduling system). The other is repetitive cyclic scheduling with various batches per product family per scheduling cycle (variable cyclic scheduling system). Second, we compared which scheduling system is superior under various manufacturing situations. The following points were noted. (1) The superior scheduling system can be shown by a two-dimensional diagram of the setup frequency and the imbalance in workload for processing among process lines in the second stage. (2) Variable cyclic scheduling is superior in comparison with basic cyclic scheduling when there is a large imbalance in the work- load to be processed among process lines in the second stage, or the workload in the second stage is larger than that in the first stage. The result of this research provides guidelines for selecting which scheduling system should be adopted. [ABSTRACT FROM AUTHOR]

We consider a firm's production and sales decisions for an age‐based product whose value increases with ageing (e.g., whisky, wine, and cheese). The firm has been selling a younger‐aged product but is considering introducing a new product by setting some of its production aside to age longer (in the "maturation" process). With a fixed production capacity dictated by the "distilling" process that takes place before the maturation process, the firm needs to decide if and when to sell different aged products as partial substitutes. Specifically, the firm must decide, period by period, how much, if any, of its younger‐aged product to set aside for additional ageing. Because the younger product has been selling for some time, the firm knows its market size. For the new product, we consider two scenarios in which the market size is either: (1) known (deterministic) or (2) not yet fully known (stochastic). For the deterministic market size scenario, we provide an analytic solution to the infinite horizon problem and show that the optimal fraction of production reserved for additional ageing increases and converges to a steady‐state solution with a closed‐form expression. Though our model is dynamic, we show that a static policy, which is easy to compute and is intuitively appealing, performs quite well. For the stochastic market size scenario, we show that a "certainty equivalence" policy is optimal under reasonable conditions, and near‐optimal when these conditions do not hold. Hence the stochastic problem is effectively equivalent to the deterministic market size case. We also examine the case when the production process is subject to a deterministic yield loss and obtain similar structural results. [ABSTRACT FROM AUTHOR]

Continuous improvement (CI) has played a key role in Japan's quality management. U.S. companies have begun to adopt CI in recent years. This paper studies the implementation of CI in seven U.S. manufacturing companies. We view values as the core concept of culture that impacts CI effectiveness. Using both qualitative and quantitative data with a sample of seven companies, we observe empirically a relationship between process-oriented values and CI effectiveness. We also find that communications involving workers is strongly associated with CI effectiveness. Finally, we find an association between process orientation and communication frequency, and argue that communications act as an intervening variable between process orientation and effectiveness. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

Cellular manufacturing systems have been proposed as an alternative to the job shop since they provide some of the operational benefits of a flow line production process, while retaining to some extent the flexibility of job shops. However, this must be balanced against the possibility of additional initial investments in equipment to form the cells and a certain loss in manufacturing flexibility, particularly in terms of the ability to deal with long-term demand changes This paper presents a model-based heuristic cell system redesign methodology to deal with such demand changes. The methodology is validated and applied to system designs generated from several data sets published in the literature. Results show that different kinds of demand changes incur distinct kinds of costs. Further, characteristics of cell designs that can handle long-term demand changes at least cost are identified. [ABSTRACT FROM AUTHOR]

Aggregate planning (AP) is a necessary activity for manufacturing and services alike. A shift toward high-volume batch and continuous flow processes within American manufacturing has given rise to increasing numbers of crew-loaded facilities. A majority of AP approaches incorporate continuous decision variables and require frequent adjustments to both production and work-force settings. Despite the availability and diversity of these approaches, few significant applications have been reported. This paper presents the detailed development of a discrete AP switching rule that can be applied to a variety of cost environments. Inventory costs are estimated using an interval approach rather than traditional point estimates. The model allows incorporation of overtime options and is interactive in nature. Decision variables from the model can be disaggregated and linked directly to lower-level planning activities. Actual results of model implementation are reported. An overview of the model's incorporation into the larger context of hierarchical production planning is found in [21]. [ABSTRACT FROM AUTHOR]

Research relating to sequencing rules in simple job shops has proliferated, but there has not been a corresponding proliferation of research evaluating similar sequencing rules in more complex assembly job shops. In a simple job shop, all operations are performed serially; but an assembly shop encompasses both serial and parallel operations. As a result of the increased complexity of assembly shops, the results associated with the performance of sequencing rules in simple job shops cannot be expected for an assembly shop. In this paper, 11 sequencing rules (some of which are common to simple job shops and some designed specifically for assembly shops) are evaluated using a simulation analysis of a hypothetical assembly shop. The simulation results are analyzed using an ANOVA procedure that identities significant differences in the results of several performance measures. Sensitivity analysis also is performed to determine the effect of job structure on the performance of the sequencing rules. [ABSTRACT FROM AUTHOR]

This paper considers a production planning model for a single-facility multiproduct problem where backlogging is not allowed. A planning-horizon theorem is derived. From that theorem, a forward algorithm for finding an optimal solution over a finite horizon and a procedure for selecting the first-period production in a rolling-horizon environment are developed. Computational results from a set of simulation experiments designed to investigate the cost effectiveness of the procedure demonstrate its effectiveness. [ABSTRACT FROM AUTHOR]

Conventional production planning methods assume the existence of a medium- or longrange demand horizon. However, demand usually is known over a much shorter range; scheduling decisions must be made within this "decision window," which rolls forward in time. This paper presents a new lower bound for lot-sizing heuristics in a rolling-horizon framework and compares it to the well-known Wagner-Whitin bound. The new bound indicates heuristic schedules that have costs close to the optimum. Rolling-horizon schedule costs are compared to corresponding static-horizon schedule costs (assuming the whole horizon is known in advance), using the ratio of decision-window size to the natural order cycle as a parameter. For values below unity, the rolling-horizon policy is significantly more costly. For values above one, the two policies have similar costs and actually converge as the parameter value increases. [ABSTRACT FROM AUTHOR]

A common characteristic of classical variance investigation models includes the assumptions that the in-control cost observations from manufacturing processes are independently and normally distributed. The purpose of this paper is to empirically assess the appropriateness of the above assumptions in an accounting setting. Several sets of data generated from manufacturing processes were examined, with the following results. First, normality and independence assumptions appeared to be violated with the daily data. In addition, several transformations commonly employed in the statistics literature did not alter this conclusion. Second, the above assumptions were not violated with the weekly data. It was then demonstrated that these findings will, in general, hold. These results, subject to the inherent limitations of a case study approach, led to the following inferences and recommendations. Using classical statistical techniques and daily data to control a process incurs costs that have been previously overlooked, costs resulting from distributional assumption violations, if these costs exceed the benefits of using daily data, a manager should (1) use classical techniques to monitor weekly data, (2) use Tache by chef inequalities to monitor daily data, and/or (3) use variance investigation models that more formally incorporate the serial dependencies of daily data. [ABSTRACT FROM AUTHOR]

Narasimhan and Wang (2000) provide a valuable addition to the research base by identifying a limitation in two of the original equations in Bozarth and Berry (1997), which we resolve, and a possible research direction for the calibration of indifference profiles. However, they fall short in their interpretation of key conceptual and methodological issues, including the distinction between indifference and ideal profiles, the difference between individual profile dimensions and overall congruence, and firm versus industry-level manufacturing strategy research. We use this opportunity to clear up these points of confusion, and to reaffirm the value of the methodology introduced in Bozarth and Berry (1997). [ABSTRACT FROM AUTHOR]

ABSTRACT: Business function‐specific stand‐alone enterprise applications (SEAs) are displacing functionally integrated enterprise resource planning (ERP) systems, despite strong empirical support for the business benefits of the latter. This study explores the conditions under which it may be more effective to use a set of SEAs instead of a single‐suite ERP system, and vice versa. Based on Organizational Information Processing Theory, we expect differences in effectiveness to grow in prominence when the uncertainty of the operating environment increases, that is, when operational glitches in production processes become more frequent. Extending the existing literature, we postulate that high functional differentiation is a precondition for SEAs to be more effective than an ERP system, hypothesizing that the level of functional interdependence ultimately determines which type of software is superior for a given production process. We test our hypotheses using data collected from 163 make‐to‐order (MTO) production processes nested within 73 manufacturing plants and seven supply chains of complex, high‐tech machinery. Results show that when functional interdependence is low, the negative effect of operational glitches on delivery performance is effectively mitigated in MTO production processes wherein process‐related information is managed predominantly using SEAs; conversely, when functional interdependence is high, using an ERP system is more effective. Our findings offer practical guidelines as to when to use SEAs versus an ERP system while also integrating and updating the findings of earlier empirical research, in which each has been analyzed separately. [ABSTRACT FROM AUTHOR]

ABSTRACT Lean concepts in manufacturing have focused on elimination of wastes within the business processes. This study investigates whether addition of radio frequency identification (RFID) technologies in the manufacturing process can complement Lean manufacturing. Specifically, will more accurate information from RFID-based solutions help achieve the goals of Lean initiatives in manufacturing plant performance and, if yes, in what specific ways? The analysis is based on a comparison of the following three automatic identification technologies: existing (one-dimensional) 1D barcode, 2D barcode, and the use of RFID in a real job-shop environment where items are manufactured for meeting actual demand and also future forecast demand. We analyze the effect of information visibility in these settings by examining the various types of wastes that are typically addressed in Lean initiatives. The results of a discrete-event simulation suggest that employing RFID in Lean manufacturing initiatives can reduce some wastes but not necessarily all types of waste. We observe an increase in overproduction waste in our setting, although other wastes are reduced with improved information visibility. Overall, our results indicate that manufacturing organizations should explore information visibility through RFID to enhance their Lean initiatives. [ABSTRACT FROM AUTHOR]

ABSTRACT In recent years, a growing number of original equipment manufacturers (OEMs) have transferred their manufacturing processes to specialized firms, known as contract manufacturers. In so doing, contract manufacturers can reduce an OEM's production costs and provide OEMs with flexibility in the production process. We examine another potential reason for the use of contract manufacturing-the potential for efficiency gains from inventory reductions. Employing econometric models and data representing manufacturing industries in the USA, we provide statistical evidence that contract manufacturing can lead to lower industry-wide inventory levels, after controlling for other relevant factors. Key managerial implications are derived from the analysis. [ABSTRACT FROM AUTHOR]

ABSTRACT Make-to-order (MTO) products may be either customized or standard, and customization can occur either at the configuration or component level. Consequently, MTO production processes can be divided into three customization gestalts: non-customizers, custom assemblers, and custom producers. In this article, we examine how the multilevel nature of customization affects order management in processes that produce complex MTO products. We first empirically validate the existence of the three customization gestalts and subsequently, analyze the order management challenges and solutions in each gestalt in a sample of 163 MTO production processes embedded in seven different supply chains. In the analyses, we follow a mixed-methods approach, combining a quantitative survey with qualitative interview data. The results show that important contingencies make different order management practices effective in different gestalts. Further qualitative inquiry reveals that some seemingly old-fashioned practices, such as available-to-promise verifications, are effective but commonly neglected in many organizations. The results also challenge some of the conventional wisdom about custom assembly (and indirectly, mass customization). For example, the systematic configuration management methods-conventionally associated with project business environments-appear to be equally important in custom assembly. [ABSTRACT FROM AUTHOR]

In this research note, we investigate segmentation opportunities for social planners such as government agencies, nonprofits, and public organizations. These opportunities arise when the potential products are vertically (quality) differentiated and the consumers are heterogeneous in their preferences toward quality. In these cases, whether to offer quality differentiated products and what quality level to choose are important decisions for a social planner. In this research note, we identify the conditions where it is socially optimal to offer either one homogenous or two quality differentiated products. We find that the resource limitations may result in a single product offering and that the quality of the product depends on the maximum surplus per unit resource consumed by the products. We also compare our findings to a profit-maximizing firm. We find that the resource limitations may cause a profit-maximizing firm to provide a better service to some consumers than the social planner. Contrary to common wisdom, we also show that the capacity limitations may force the social planner to act like a profit-maximizing firm in terms of its pricing and product mix choice. [ABSTRACT FROM AUTHOR]

A major challenge for managers in turbulent environments is to make sound decisions quickly. Dynamic capabilities have been proposed as a means for addressing turbulent environments by helping managers extend, modify, and reconfigure existing operational capabilities into new ones that better match the environment. However, because dynamic capabilities have been viewed as an elusive black box, it is difficult for managers to make sound decisions in turbulent environments if they cannot effectively measure dynamic capabilities. Therefore, we first seek to propose a measurable model of dynamic capabilities by conceptualizing, operationalizing, and measuring dynamic capabilities. Specifically, drawing upon the dynamic capabilities literature, we identify a set of capabilities-sensing the environment, learning, coordinating, and integrating-that help reconfigure existing operational capabilities into new ones that better match the environment. Second, we propose a structural model where dynamic capabilities influence performance by reconfiguring existing operational capabilities in the context of new product development (NPD). Data from 180 NPD units support both the measurable model of dynamic capabilities and also the structural model by which dynamic capabilities influence performance in NPD by reconfiguring operational capabilities, particularly in higher levels of environmental turbulence. The study's implications for managerial decision making in turbulent environments by capturing the elusive black box of dynamic capabilities are discussed. [ABSTRACT FROM AUTHOR]

The subject of this article is the simultaneous choice of product price and manufacturing capacity if demand is stochastic and service-level sensitive. In this setting, capacity as well as price have an impact on demand because several aspects of service level depend on capacity. For example, delivery time will be reduced if capacity is increased given a constant demand rate. We illustrate the relationship between service level, capacity, and demand reaction by a stylized application problem from the after-sales services industry. The reaction of customers to variations in service level and price is represented by a kinked price-demand-rate function. We first derive the optimal price-capacity combination for the resulting decision problem under full information. Subsequently, we focus on a decision maker (DM) who lacks complete knowledge of the demand function. Hence the DM is unable to anticipate the service level and consequently cannot identify the optimal solution. However, the DM will acquire additional information during the sales process and use it in subsequent revisions of the price-capacity decision. Thus, this decision making is adaptive and based on experience. In contrast to the literature, which assumes certain repetitive procedures somewhat ad hoc, we develop an adaptive decision process based on case-based decision theory (CBDT) for the price-capacity problem. Finally, we show that a CBDT DM in our setting eventually finds the optimal solution, if the DM sets the price based on absorption costs and adequately adjusts the capacity with respect to the observed demand. [ABSTRACT FROM AUTHOR]

Effective product development requires firms to unify internal and external participants. As companies attempt to create this integrated environment, two important questions emerge. Does a high level of internal integration lead to a higher level of external integration? In the context of product development, this study considers whether internal integration in the form of concurrent engineering practices affects the level of external integration as manifested by customer integration, supplier product integration, and supplier process integration. External integration, in turn, may influence competitive capabilities, namely product innovation performance and quality performance. Second, using contingency theory, do certain contextual variables moderate the linkages between integration strategy (external and internal) and performance? Specifically, this study considers whether uncertainty, equivocality, and platform development strategy change the relationships among internal integration, external integration, and competitive capabilities. Data collected from 244 manufacturing firms across several industries were used to test these research questions. The results indicate that both internal and external integration positively influence product innovation and quality and ultimately, profitability. With respect to contingency effects, the results indicate that equivocality moderates the relationships between integration and performance. [ABSTRACT FROM AUTHOR]

The widespread recognition of the detrimental effects of high yield variation in advanced manufacturing technology settings, both in terms of cost and management of production processes, underscores the need to develop effective strategies for reducing yield variation. In this article, we report the findings of a longitudinal field study in an electromechanical motor assembly plant where we examined how the application of process knowledge by production work teams can reduce yield variation. We propose and provide an operationalizion of a strategy to identify the sequence of particular types of actions—actions to control the mean followed by actions to control the variance—that work teams should pursue over time to apply process knowledge for reducing yield variation. The results of our empirical analysis show that yield variation was significantly reduced on three of the four production lines at the manufacturing plant that served as our research site. Differences in strategies for applying process knowledge help explain the different results on each of the production lines. [ABSTRACT FROM AUTHOR]

Firms are utilizing an array of manufacturing practices in their quest for survival and success in the marketplace. The implementation of those practices has not always resulted in success stories as the focus had been mostly on technical issues, with little concern for“soft issues.” For example, the enabling role of organizational culture has often been ignored. Using Schein's conceptualization of culture as underlying assumptions, espoused values, and artifacts, we examine a framework that relates culture and manufacturing practices to performance. The underlying assumption of customer orientation is posited to affect espoused values such as beliefs on investing in facilities and equipment to leverage intellectual work and to promote creativity, beliefs on working with others, beliefs on making decisions that are global, beliefs on management control, and beliefs on integrating with suppliers. The espoused values are hypothesized to affect visible attributes of culture (behaviors) such as time-based manufacturing practices, which firms are employing for competitive advantage. A sample of 224 firms is used for developing research instruments and testing the hypothesized relationships advanced. Results indicate that high levels of customer orientation lead to a set of managerial beliefs that are collaborative and integrative. In turn, certain espoused values support a high level of time-based manufacturing practice, which leads to high performance. [ABSTRACT FROM AUTHOR]

A total of 411 subjects participated in two decision-making experiments in order to examine the effectiveness of new product development project continuation decisions. Using escalation of commitment theory, in Study 1, individual versus face-to-face team decision-making effectiveness was compared. Study 2, an extension of Study 1, compared the new product development decision-making effectiveness of individuals, face-to-face teams, and virtual teams. A virtual team is a geographically and temporally dispersed and electronically communicating work group. In Study 2, the virtual teams communicated asynchronously via groupware technology. Our findings suggest that teams make more effective decisions than individuals, and virtual teams make the most effective decisions. [ABSTRACT FROM AUTHOR]

A large-scale random sample is used to empirically examine the relationships between implementation of Advanced Manufacturing Technology (AMT) and three organizationlevel measures that have historically been attributed to AMT, but not fully tested along the AMT spectrum: market-oriented flexibility of the production process, organizational integration of production processes, and administrative intensity of the organization. Results indicate that as an organization moves along the technology scale from stand-alone AMT (e.g., CNC machines) through functionally oriented AMT (FMS and CAM) toward CIM, not only do its production processes become more integrated with each other, but those processes become more integrated with other functional systems of the organization, and the quality and timeliness of production information increase. Furthermore, this relationship becomes stronger as companies increase their level of implementation for the latter two technologies. Conversely, market-oriented flexibility decreases and administrative intensity is not observed to change as companies move along the technology spectrum. Future research should examine how organizational redesign and implementation strategies that accompany AMT implementation can concomitantly enhance organizational integration of the production process and market-oriented flexibility. [ABSTRACT FROM AUTHOR]

Investment in information systems and technology is often justified as a necessary strategy for coping with the increased complexity and information needs of today's manufacturing environments. However, the world class manufacturing paradigm suggests that increased complexity is not always necessary to meet the needs of markets and customers. Galbraith's (1973, 1977) seminal information-processing model is applied to a manufacturing environment, supported by the world class manufacturing paradigm, to test the role of various information-processing alternatives for coping with increased environmental complexity. Moderated regression and multiple discriminant analysis are used to test hypotheses in a sample of 164 manufacturing plants. Environmental complexity was found to be related to manufacturing performance for each of the five dependent variables. This relationship was moderated by at least one information-processing alternative for each dependent variable, including self-contained tasks, lateral relations, and environmental management strategies for reducing manufacturing, supplier, and goal diversity. Investments in information systems and reduction of labor and customer diversity did not moderate this relationship. Practices that were found to be particularly effective in moderating this relationship included the use of multifunctional employees, communication of manufacturing strategy, coordination of decision making, product design simplicity, reduction of parts counts, supervisory interaction facilitation, recruiting and selection for flexible employees, JIT practices, blanket purchase orders, and strong customer relationships. [ABSTRACT FROM AUTHOR]

Empirical studies for achieving manufacturing flexibility goals have centered around the uses and advantages of advanced technology. Few studies have examined alternative ways of attaining flexibility objectives. Strategic sourcing finds mention in the literature as a potential route to manufacturing flexibility. However, little empirical evidence exists to validate this view. Literature also describes manufacturing flexibility as a multidimensional concept but fails to adequately examine the synergies among the different dimensions. This research investigates the influence of strategic sourcing and advanced manufacturing technologies on specific manufacturing flexibilities, and examines relationships among different flexibilities. The results are tied to manufacturing cost reduction. The findings suggest that strategic sourcing can assist in the achievement of modification flexibilities. Volume and modification flexibility are found to influence new product flexibility. Modification flexibility is found to influence manufacturing cost reduction. The results show that strategic sourcing can be used to target specific manufacturing flexibilities and that interflexibility synergies need to be considered while formulating flexibility-based manufacturing strategies. [ABSTRACT FROM AUTHOR]

Product development occurs in multiproject environments where preemption is often allowed so that critical projects can be addressed immediately. Because product development is characterized by time-based competition, there is pressure to make decisions quickly using heuristics methods that yield fast project completion. Preemption heuristics are needed both to choose activities for preemption and then to determine which resources to use to restart preempted activities. Past research involving preemption has ignored any completion time penalty due to the forgetting experienced by project personnel during preemption and the resulting relearning time required to regain lost proficiency. The purpose of this research is to determine the impact of learning, forgetting, and relearning (LFR) on project completion time when preemption is allowed. We present a model for the LFR cycle in multiproject development environments. We test a number of priority rules for activity scheduling, activity preemption, and resource assignment subsequent to preemption, subject to the existence of the LFR cycle, for which a single type of knowledge worker resource is assigned among multiple projects. The results of the simulation experiments clearly demonstrate that LFR effects are significant. The tests of different scheduling, preemption, and resource reassignment rules show that the choice of rule is crucial in mitigating the completion time penalty effects of the LFR cycle, while maintaining high levels of resource utilization. Specifically, the worst performing rules tested for each performance measure are those that attempt to maintain high resource utilization. The best performing rules are based on activity criticality and resource learning. [ABSTRACT FROM AUTHOR]

Telephone repair process and performance relationships are modeled using a structural equation approach. The basic structure of the causal model is a function of process flow. The data analysis and modeling approach advocated here can be applied to any manufacturing or service process that has a recurrent process flow and good internal and external performance data. Our primary objectives are to define quantitatively (1) how the performance of repair persons dispatched to the customers' premises is related to automatic testing and repair, and (2) how internal process performance is linked to external customer satisfaction. A secondary objective of this article is to explain briefly some of the practical problems of modeling process-level performance relationships. Results indicate that the structural equation models are statistically significant and have a meaningful interpretation. Examples of "what if' scenarios using these structural equation models are presented to help managers predict customer satisfaction levels given certain process performance improvement set standards of performance, and better understand the interdependencies between labor and automation resources in this telephone repair process. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

The advent of the wide variety of new, highly integrated, advanced manufacturing technologies available for acquisition by a firm's managers has brought to light an accompanying set of unexpected issues. These issues include expectations for the benefits and costs of these technologies, determining the appropriate order of implementation and finding a way to justify acquisition when many of the benefits are a function of the technology's learning and synergistic effects on other operations and technologies. We present here a model that captures the interaction effects of these highly integrated technologies and discuss the data requirements for application of the construct. We then illustrate the model's workings with a number of multitechnology examples and show the danger of ignoring the synergistic and learning effects of these technologies when considering their acquisition. [ABSTRACT FROM AUTHOR]

We show that the problem of determining lot sizes in a multistage assembly system for the case of instantaneous production and constant demand for the end item can be reduced to the problem of determining relative frequencies of production/order for items at each production stage. We further show that such frequencies are independent of the demand levels. Optimal and near-optimal solution procedures for this reduced problem are provided. The near-optimal procedure successively treats each stage of production as a final production stage while simultaneously incorporating decisions made at lower stages into decisions made at higher stages. Experimental results show that the near-optimal procedure results in optimal solutions 75 percent of the time and performs considerably better than representative heuristics available in the literature. Further, its performance is relatively less susceptible to product/structural characteristics of the system. [ABSTRACT FROM AUTHOR]

A descriptive life cycle model of process development and innovation, as previously reported, is used as a framework to analyze historical trends in the technological development of U.S. automotive engine plants. Using the plant as the unit of analysis, the author examines trends in product diversity, equipment development, backward integration, and productivity improvement. Results support the original research framework and help to clarify the important impact of process changes on the sources of productivity improvement, the capability for product innovation, and the cost of change. [ABSTRACT FROM AUTHOR]

This research examines the adoption of operations research techniques by manufacturing organizations. The study includes the frequency of use, techniques used, organizational units and the number of personnel, types of problems analyzed, overall results achieved, and problems encountered among various sizes of firms and industry classes. [ABSTRACT FROM AUTHOR]

The complexity of the process through which new technology is developed requires the use of multivariate models and research hypotheses. However, few studies of innovation have attempted these tools; because of the expense of obtaining large enough samples and the qualitative or nominal nature of most data on technical change. Descriptive data are available for one large sample (n = 567) of new products and processes. Five industries are represented. These data include characteristics of the innovations such as cost and change required in the production process, and characteristics of the basic information used in their development, such as its source and initiation. While there are severe limitations and problems of reliability and validity for the data, some encouraging results have been obtained using a multivariate binary classification technique to test several hypotheses. Industry differences have been predicted on the basis of various characteristics of their successful renovations (R² = 0.27) and on the basis of communication characteristics (R² = 0.17). Some more rigorous approaches are suggested for future work. [ABSTRACT FROM AUTHOR]