Pär Åhlström

Assessing changes towards lean production

Develops a model which operationalizes the different principles in lean production, with a focus on those that concern the work organization in the manufacturing part of a company. The model has been developed using available theory and has also been tried out in a clinical field study. The model has implications both for research and practice. For research, it can be used as a model for operationalizing lean production to be able to study change processes properly. In practice, the model can be used as a tool to assess the development taking place in an effort to become lean. Finally, it can be used as a checklist for what to aim at when trying to implement lean production. Lean should be seen as a direction, rather than as a state to be reached after a certain time and, therefore, the focus lies on the changes in the determinants, not on their actual values.

The difficult path to lean product development

Lean product development holds the promise of dramatically improving a companys competitive position. Its implementation offers the potential for faster product development with fewer engineering hours, improved manufacturability of products, higher quality products, fewer production start-up problems, and faster time to market. Of course, all of this improves the likelihood of market success. As Christer Karlsson and Par Ahlstrom point out, however, a company attempting to implement lean product development must overcome numerous obstacles. By spending more than 2 years observing and facilitating one companys efforts to make this transition, they were able to identify various factors that either hinder or support the implementation of lean product development. Lean product development comprises numerous interrelated techniques, including supplier involvement, cross-functional teams, concurrent engineering, integration (as opposed to coordination) of various functional aspects of each project, the use of a heavyweight team structure, and strategic management of each development project. However, a company does not achieve lean product development simply by implementing some of these techniques. A successful move toward lean product development requires approaching these interrelated techniques as elements of a coherent whole. As observed in the subject company, several factors can hinder attempts to achieve lean product development. For example, managerial overemphasis on RD close cooperation with a qualified customer, who can provide vital information as well as challenge the development team; highly competent engineers; and, most important, the active, ongoing support and participation of top management. Most participants in the process examined in this study seemed interested in the possibilities of lean product development, which suggests that motivation to change may not pose a significant problem in similar efforts.

Change processes towards lean production

Explores the role of the management accounting system in the process of adopting a complex manufacturing strategy, lean production. Finds, in a longitudinal field study, using the clinical methodology, that in order to change the management accounting system to support the adoption of lean production, traditional performance measures have to reach a certain threshold. An important way to create impetus for this change is to raise the level of the unit of analysis in the management accounting system, both horizontally and vertically. Finally, the management accounting system affects the process in three concurrent ways: technically, through its design; formally, through its role in the organization; and cognitively, through the way in which actors think about and use the management accounting system. Proposes that in order for the system to be congruent with lean production principles, all three of these perspectives need to be changed.

An instrument for assessing lean service adoption

Purpose – The purpose of this paper is to develop and empirically validate an instrument containing operational measures of lean service. The instrument is intended for use by both researchers and practitioners.Design/methodology/approach – The instrument was developed and validated in an iterative process between theoretical and empirical insights. Drawing on a wide selection of frequently cited papers on lean service, a preliminary list of items was generated. These items were then vetted through four steps in order to achieve high validity. Empirical refinement and validation included workshops and semi‐structured interviews with expert practitioners, as well as testing the instruments ability to discriminate between high and low adoption of lean and portray changes during lean service adoption.Findings – The instrument contains 34 items that assess enablers of lean adoption, lean practices, and operational performance. Empirical validation suggested the instrument was able to discriminate between hig...

Top management control and knowledge creation in new product development

Purpose – The purpose of this paper is to examine the role of top management control in stimulating innovation through their effect on the creation of knowledge in new product development (NPD) projects. Top management has a crucial role in stimulating innovation in companies, in particular as top managers affect knowledge creation through their interaction with project teams before and during an NPD project, which can of course affect innovation.Design/methodology/approach – Through comparative case‐based research in two companies in high‐velocity industries, chosen through theoretical sampling, the authors have studied six NPD projects.Findings – The control top management exercise over an NPD project influences the creation of knowledge in different ways, both hampering and facilitating knowledge creation. In particular, this control focuses on explicit knowledge, and not tacit knowledge, which may reduce the overall capacity for knowledge creation and ultimately innovation.Research limitations/implica...

Sequences of manufacturing improvement initiatives: the case of delayering

Changes in manufacturing often result in decision making being decentralised. As a consequence of the decentralisation of decision making, the number of hierarchical levels in the organisation is often reduced. This paper examines when a delayering of the organisation takes place during manufacturing improvement. For two and a half years, the authors participated in and studied one company’s implementation of lean production. The observations from the clinical study are compared with existing operations management theory. The findings indicate the importance of delayering the organisation early during manufacturing improvement, to create a platform for further improvement.

Dimensions of change in make or buy decision processes

Purpose – The purpose of this paper is to determine the dimensions along which make or buy decision processes change over time.Design/methodology/approach – The paper is based on a longitudinal in‐depth case study of a large industrial company, where the data were collected using interviews, documentation and observations. The data were analyzed using chronological patterns, and findings were then compared with the literature on make or buy decision processes.Findings – Nine dimensions were found along which the make or buy decision process had changed over time. The dimensions were cross‐functionality, structure, regularity, formality, awareness, mandatory, information distribution and management and flexibility. The causes of the changes were related to a combination of company internal and external events and contexts.Research limitations/implications – The findings should be seen as a first attempt in assisting in the creation of a foundation for constructing more dynamic make or buy decision process ...

Converging production models: the STS versus lean production debate revisited

Purpose - Against the background of the often politicized debate on the advantages and disadvantages of production models based on sociotechnical systems (STS) theory and lean production (LP), this ...

Perspective: Changing product devleopment strategy—A managerial challenge

Abstract By changing its product development strategies to match more closely the wants and needs of the marketplace, a firm can transform product development into a formidable competitive weapon. Just as formidible, however, is the effort that this transformation requires. Established organizational structures and corporate politics present significant barriers to acheiving fundamental changes in product development strategy. Christer Karlsson and Par Ahlstrom present a case study of one firms efforts to build capabilities for creating new products quickly and efficiently. Rather than focus on the content of the firms product development strategies, however, they emphasize the process this electromechanical manufacturing firm used for changing its product development strategy. Drawing on their experiences as clinical researchers in this effort, they describe key lessons learned during the change process, and they offer suggestions for managing the process of changing product development strategy. They highlight five key lessons learned during the strategy development process. First, rather than viewing product development as a line function, a firm should view product development as a key executive area with responsibility for the companys competitive position. Second, market issues are the responsibility, not only of marketing, but also of product development and production. Third, to avoid corporate myopia, management control systems must consider not only time and money, but also acheivement of goals. Fourth, strategic planning flows more smoothly if the participants start by mapping the firms past and present position before attempting to define the desired position. Finally, formulation of a product development strategy is the responsibility of a multifunctional team of executives. Managers should keep a few rules in mind when devising a process for formulating a product development strategy. First, adopt a learning strategy throughout the change process. Formulation of a product development strategy involves many abstract concepts, and a successful strategy requires cross-functional consensus. Second, combine tangible, direct activities with long-term strategic aims. Third, avoid the pitfall of best practice. The form that the product development organization takes depends, to a great extent, on the type of development work. Finally, before discussing future strategies, the strategy formulation process should focus on analyzing the current situation.

Organizational Slack and Knowledge Creation in Product Development Projects: The Role of Project Deliverables

Our concern is with how changes in organizational slack affect knowledge creation in product development projects. We operationalize a change in organizational slack as changed possibilities to depart from project deliverables in NPD projects. Through case research in high velocity industries we identify the effect a change in organizational slack has on knowledge creation processes inside product development projects. In particular we highlight the effects on tacit and explicit knowledge. More specifically we find that reduced slack creates a focus on explicit knowledge rather than tacit knowledge, which may reduce the ability to create knowledge creation and ultimately to innovate.