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Rolling out lean operations practices in MNCs’ plants is a complex knowledge transfer process whose design and implementation, though critical to operations performance, to date has not been investigated by operations management, international business, strategy, and organizational design research. Applying conceptual tools drawn from various theoretical approaches to knowledge management, transfer and diffusion, this exploratory study: (a) classifies and interprets lean roll-out processes in MNCs, framing them in terms of (i) knowledge replication strategies (template vs. principles-based), (ii) decentralization of decision making (degree of plant autonomy), and (iii) type of organizational ambidexterity (structural vs. contextual) underlying the process; (b) develops, through seven case studies of lean roll-outs in MNCs’ plants, three testable propositions about what might enhance the lean roll-out process performance, arguing about the individual and combined effect of the three above mentioned dimensions on lean roll-out effectiveness and efficiency. We posit that an approach characterized by principles-based knowledge replication, larger decentralization, and prevalence of contextual ambidexterity positively impacts on roll-out process performance.

Adopting a knowledge-based perspective, the purpose of this paper is to investigate the roll-out process of lean production systems and explores the dimensions that might enhance or hinder its performance. It develops a framework to understand and design lean roll-out processes, identifying the research dimensions/design variables to classify and interpret such processes.

This exploratory multiple case study analyses seven lean roll-out processes in multinational companies’ plants. An original data set, developed on the basis of a purposely design research protocol, was built through two rounds of plant visits and structured interviews. The cross-case analysis compares and contrasts the lean roll-out processes according to the research dimensions constituting the framework.

The effectiveness and the efficiency of the lean roll-out processes: first, negatively co-vary with the degree of lean knowledge codification; second, positively co-vary with the degree of autonomy of the plant; third, positively co-vary with the degree of contextual ambidexterity. Moreover, lean roll-out processes characterized by principles-based knowledge replication strategy, plant autonomy and contextual ambidexterity are comparatively more effective and efficient.

This is an exploratory qualitative study that develops propositions potentially testable in larger scale, more analytical research.

This study provides a tentative roadmap to successfully approach the roll-out of lean production systems in complex organizations.

This study challenges the current theory and practice which implicitly assumes that lean roll-outs take place linearly, cascading a set of predefined lean operations practices. Instead, the authors show that a less codified, more decentralized and contextually ambidextrous approach might be more effective.

Overview All organisations are, in one sense or another, involved in operations; an activity implying transformation or transfer. The major portion of the body of knowledge concerning operations relates to production in manufacturing industry but, increasingly, similar problems are to be found confronting managers in service industry. It is only in the last decade or so that new technology, involving, in particular, the computer, has encouraged an integrated view to be taken of the total business. This has led to greater recognition being given to the strategic potential of the operations function. In order to provide greater insight into operations a number of classifications have been proposed. One of these, which places operations into categories termed factory, job shop, mass service and professional service, is examined. The elements of operations management are introduced under the headings of product, plant, process, procedures and people.

There has been a growing call from within the operations management (OM) academic community for research of more managerial relevance. This has implied a greater emphasis on empirical research: surveys, cases, and action research. But in fact these types are quite different. However, the great majority of empirical OM work published is based on postal surveys and/or interviewing executives, where research method selection is made for reasons of practical convenience and academic expectation. Given the level of complexity involved in understanding the OM perspective of business issues then the emphasis should be placed on plant‐based research. Conducting research on‐site and investigation through the analysis of relevant data, issues, developments and events ensures relevance and a validity essential to making an impact on business practice. There are obstacles to increasing the amount of plant‐based research which is carried out, such as practical and personal difficulties, a mistaken concern over research rigour, and academic institutional inertia. Each of these needs to be overcome if OM research is to influence business practice more in the future than it has in the past.

Utilization of off‐highway vehicles forms an essential part of UK industry's efforts to augment the productivity of plant operations and reduce production costs. However, uninterrupted utilization of plant and equipment is requisite to reaping the maximum benefit of mechanization; one particular problem being plant breakdown duration and its impact upon process productivity. Predicting the duration of plant downtime would enable plant managers to develop suitable contingency plans to reduce the impact of downtime. This paper presents a stochastic mathematical modelling methodology (more specifically, probability density function of random numbers) which predicts the probable magnitude of ‘the next’ breakdown, in terms of duration for tracked hydraulic excavators. A random sample of 33 machines was obtained from opencast mining contractors, containing 1070 observations of machine breakdown duration. Utilization of the random numbers technique will engender improved maintenance practice by providing a practical methodology for planning, scheduling and controlling future plant resource requirements. The paper concludes with direction for future research which aims to: extend the model's application to cover other industrial settings and plant items; to predict the time at which breakdown will occur (vis‐à‐vis the duration of breakdown); and apply the random numbers modelling to individual machine compartments.

Plant configuration management systems address all phases of the plant’s life cycle, from engineering design, re‐design, maintenance, to operations. However, as yet little research has been reported on plant configuration management information systems analysis. During the past decade, the object‐oriented approach has received much attention in information systems development. This paper describes an object structure for plant configuration management systems analysis. Three major aspects of configuration management (maintenance, re‐design change, and business process) and fundamental types of objects engaged in configuration management are described. The association between these objects is then built through identifying the messages between the objects. Practical application of this framework shows that it is useful for the analysis and design of a plant configuration management information system.

The purpose of this paper is to examine the impact of operations and maintenance (O&M) practices, individually and collectively, on power plant performance.

Data were collected from more than 100 power plants in Australia and Malaysia. The reliability and validity (content, construct, and criterion) of the practice and performance measures were evaluated.

Committed leadership and maintenance-oriented practices as part of a total productive maintenance (TPM) philosophy were found to be the main differentiators between high and low performing plants.

The research is cross-sectional in nature, therefore, it does not permit us to account for the lag between implementation and performance. Second, the performance measures are subjective and may be subject to response bias.

The implication of the research findings for plant managers is that they need to allocate more “softer” resources to the O&M function if they expect high plant availability.

Apart from capacity and fuel cost, operating costs are an important source of differentiation for power plants. The implication is that reduction in operating costs is directly related to the reduction of consumer power bills.

The reader will learn from this paper that committed leadership and maintenance-oriented practices have greater explanatory power in the regression models than employee involvement, customer focus, strategic planning, and knowledge management. This knowledge is important because it emphasises that in addition to quality management practices, which are focussed on the development of the people aspects of the organization, the plant equipment and physical assets should also be given equal emphasis, in order to improve operational performance of power plants.

With the increasing technological innovation in the automotive industry, the need for complementary innovations in worker organization has arisen. In response to this need, two distinct approaches for teamwork in automotive production have been developed. This paper discusses both the Japanese and the Scandinavian teamwork models and their various implementations found among auto manufacturers worldwide. Work teams must be supported by changes in production philosophy, intensive training programs, and enhanced labor‐management relations. These complementary systems require significant investments, making team building a risky but potentially valuable venture. New insights on team building and its implications for production processes are provided.

The “robust networks” concept of Ferdows is examined and related to other key theories from the manufacturing strategy literature, resource‐based and other conceptualisations of the organisation of innovation in international networks, and the international business debates on “operational flexibility”. The cases of seven international automotive assemblers with operations in Brazil are then considered in the light of Ferdows’ framework and the external factors bearing on the country and the sector within it. It is evident that, among the global assemblers, the “world” car strategy is dominant, leading to a concentration on the “source” and “lead” roles for individual plants, often combined with radical logistical arrangements. This seems in turn to support the argument for “robustness” rather than “operational flexibility”. Suggestions are made for further work to study the luxury car assemblers and other sectors where economies of scale are less important and where there is a greater degree of global dispersion of production facilities.

The chemical plant (CP) maintenance industry has been under increasing pressure by process designers to demonstrate its evaluation and information management of model checking (MC) on the durability’s performance and design of plant control instrument. This main problem has been termed as imperfect maintenance actions (IMAs) level. Although IMAs have been explored in interdisciplinary maintenance environments, less is known about what imperfect maintenance problems currently exist and what their causes are, such as the recent explosion in the Beirut city (4 August 2020, about 181 fatalities). The aim of this paper is to identify how CP maintenance environments could integrate MC within their processes.

To achieve this aim, a comprehensive literature review of the existing conceptualisation of MC practices is reviewed and the main features of information and communication technology tools and techniques currently being employed on such IMA projects are carried out and synthesised into a conceptual framework for integrating MC in the automation system process.

The literature reveals that various CP designers conceptualise MC in different ways. MC is commonly shaped by long-term compliance to fulfil the requirement for maintaining a comfortable durability risk on imperfect maintenance schemes of CP projects. Also, there is a lack of common approaches for integrating the delivery process of MC. The conceptual framework demonstrates the importance of early integration of MC in the design phase to identify alternative methods to cogenerate, monitor and optimise MC.

Thus far, this study advances the knowledge about how CP maintenance environments can ensure MC delivery. This paper highlights the need for further research to integrate MC in CP maintenance environments. A future study could validate the framework across the design phase with different CP project designers.