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Over the last few years, several international studies have independently shown a significant correlation between the number and intensity of manufacturing practices in use and the performance of a firm. The conclusion is an unsettling: “the more the better.” This paper uses the Global Manufacturing Research Group’s (GMRG) second round database to deepen our understanding of this relationship. The shape of a scatterplot of practices versus performance resembles the shape of an American or rugby football and is often called the “performance football”. The performance football seems to be a general phenomenon so, as practices are added, a firm should garner earlier performance improvements if it followed the upper edge of the performance envelope. This is consistent with the “sandcone” model or sequential capability building model that suggests that a firm should first invest in quality practices and then add others over this base. We first demonstrate the relationship between practices and performance holds for the GMRG data and then we make detailed comparisons of the firms along the upper and lower edges of the football. The comparisons provide some evidence that there is a sandcone effect.

Small and medium enterprises (SMEs) are recognized as playing a pivotal role in the economic growth and technological progress of many countries, yet there is a dearth of research that examines the operational performance and strategies of these smaller enterprises, especially in the Asian context. Of particular interest is the operational posture in terms of the key operations priorities adopted by successful SMEs in carving out their own competitive niches. This study is the first to develop a taxonomy of operations strategies based on the operational performance of high performing SMEs in Singapore. As Singapore is one of the most competitive countries in the world and a highly successful newly industrializing nation in Asia, the use of Singapore data provides benchmarking and best practice information for international business communities and newly industrializing countries. Three strategic clusters were identified. Analysis showed significant differences in the operational posture, financial performance and the kinds of improvement programs undertaken by the three strategic clusters. The strategic role of operations in terms of its contribution to corporate strategic formulation and financial profitability was also investigated. Managerial implications of our findings are presented.

The purpose of this paper is to introduce the notion of fitness in production as something different from leanness and show that building fitness puts a factory on a course of developing cumulative capabilities and improving its ability to respond to changing market and business conditions.

The paper examines the process of design, launch, and management of a fitness program in 42 factories of the Hydro Aluminum Extrusion Group on five continents between 1986 and 2001. The design was based on the “sandcone model” proposed by Ferdows and DeMeyer but the sequence of capabilities was modified to improve safety, reduce process variability, codify and share tacit production know‐how, improve responsiveness, and improve labor and machine efficiency.

Most factories showed improvements higher than industry average in these capabilities during the 15 years. Moreover, they improved the capabilities listed earlier in the above sequence faster than those listed later, indicating that they were becoming more fit.

Observations were in only one company and industry, which limits general applicability of the model. However, measurements were taken over a relatively long period, factories were spread on five continents, and the authors had access to the actual data during the 15 years, which together provided a unique opportunity to gain deep insights from this case. Future research should test the applicability of the model in other industries and companies.

A fitness regimen provides a roadmap for improving core capabilities in a factory. It is different from building leanness. Fitness helps the factory become leaner, but the opposite is not always true. A factory can become too lean but never too fit.

This paper is the first, to the authors' knowledge, to introduce the notion of fitness in production in the literature. Results observed in this case suggest that a better understanding of how factories become fitter provides insights into some of the deeply ingrained practices of superior manufacturers, especially those that stay competitive over long periods.

Addresses how organizations are approaching Business process management. Following interviews in “leading edge” organizations, qualitative analysis has revealed key themes which may help inform others at an earlier stage in developing their approach to business process management. Presents research propositions, based on these themes, and on a categorization of business processes into operational, support, direction setting and managerial processes. There are implications for operations management in both the probable order of addressing these process categories and in the applicability of techniques and concepts from operations management.

The purpose of this paper is to know which growth-impeding constraints are perceived to act upon operations of small- to medium-sized (SME) companies by their owner-managers and to recommend transitionary paths to elevate constraints and increase contribution levels made by SMEs’ operations. To do so, this research has been primarily founded upon Hayes et al.’s (2005) operations contribution model for differentiating between different levels of operations’ contribution, and secondarily on the theory of constraints philosophy to explain the perceptions of constraints found at each level – current and future.

An open-ended survey and a series of group workshops have gathered new empirical data about these perceptions, which were coded using the relational content analysis to identify a parsimonious set of perceptual growth-impeding constraint categories. The most popular transitions were identified and a correlation of frequency rank orders between “perceived current” and “perceived future” constraints categories was calculated, and likely transitionary paths for growth are discussed. Three SME case studies were documented in related action research to contextualise survey findings.

The most popular transition was from “neutral” to “leading”. A lack of people capability was perceived to be the most commonly reported growth-impeding constraint category, followed by a combined lack of process competence and product and service innovation, further followed by a lack of skills in information technology automation. In addition, a new conceptual model has been generated inductively to address shortcomings found in the original operations contribution model (Hayes et al., 2005) during its application to UK SMEs. The new model is referred to in this paper as the “Operations Growth Rocket”.

This research only used data from UK SMEs.

This work should help SME owner-managers to overcome growth-impeding constraints that act upon their operations and assist them to develop more effective actions and paths to increase the contribution levels made by their operations. This in turn should support growth of their organisations. Findings will also inform teaching about more effective operations management in SMEs.

This work should help UK SMEs to grow, which in turn will strengthen the UK economy.

A novel approach and new data from 208 SMEs modify a classical operations contribution model (Hayes et al., 2005). This is achieved by considering transitionary paths to be meta-categories continua abstracted from constraint categories combined with case data for moving towards higher levels of operations contribution, rather than using discrete growth-impeding and growth-constraining “levels”. This research has inductively generated a new version of the classical contribution model that should be more suitable for stimulating growth in (UK) SMEs.

Effective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor efficiency measures sufficed when all that was made could be sold or when mass production systems filled warehouses with stock and the OMS had little relationship with “the consumer.” Modern manufacturing systems require a different form of flow optimization (beyond labor efficiency) measurement (Schmenner, 2015). The essential unit of measure for all OMS designs is the optimal use of time for process value adding and the flow of materials into and from the conversion process. Timely flow, therefore, satisfies the needs of multiple organizational stakeholders including cash flow (accounting), consumer reaction times (marketing) and the general steady state flow of materials (sales and supply chain). The purpose of this paper is to present the results of testing a new performance measure of operations flow effectiveness (OFE) with ten purposively selected cases.

The paper is theory building using ten, purposively selected, longitudinal case studies drawn from the UK high-value manufacturing (HVM) sector using a pluralist methodology of interviews, observation and secondary data.

The OFE measure provides a holistic view of material flow through the input-process-output cycles of a firm. The measure highlights OMS design weaknesses and flow inhibitors that reduce cash flow using a time-based approach to measuring OMS performance. The study validates the OFE measure and has identified six key design elements that enable high flow performance.

The paper tests a new process-focused flow performance measure. The measure supports a holistic approach to the manufacturing enterprise and allows different OMS designs to be evaluated so that organizational learning may be enacted to support performance improvement.

The manufacturing strategies and practices in a number of newly industrialising countries (NICs) are studied. The IMSS data for four Latin American industrialising countries, referred to as Group 1, are analysed, comparing these with two benchmarks, which represent more advanced manufacturing situations in well established industrialised countries. Comparing results indicated similarities for Group 1 with the two benchmarks, on simultaneously aiming at all their competitive goals. The study also proved a mismatch in their emphasis on the goals and the level of the objectives achieved in this regard. Links for this mismatch were searched for in various areas including human resource and technological aspects. Results also highlighted serious shortcomings for Group 1 in process technology criteria as compared with the two benchmarks. Comparison results with regard to human resources as well as planning and control aspects are also discussed in the paper. Based on this study, it has been concluded that environmental features have to be thoroughly analysed before any manufacturing strategy is developed for the firms in NICs. Further, continual interactions between manufacturing strategies for these firms with their environmental features have to be included in their strategy formulation process.

The purpose of this paper is to reaffirm the suggestion that there are at least two distinct types of laws of trade-off that affect all firms and, in doing so, to contribute toward resolving the persistent trade-off debate in the literature.

Conceptual study using implicit deductive reasoning.

Two types of trade-offs are identified: “internal” can be understood following the dictates of the law of diminishing returns, while “external” can be modeled using the principle of energy conservation.

New insights are provided by discussing the impact of both laws of trade-off on the resource-based view of the firm, on new capabilities such as sustainability and innovativeness and on key strategic choices.

The study explains why trade-offs occur and outlines contextual factors that determine the “strength” of the trade-offs.

To the best of the authors’ knowledge, no previous study has attempted to investigate the topic of strategic trade-offs on the basis of the principle of energy conservation.

Examines the adoption and strategic use of advanced manufacturing technologies (AMTs) by small manufacturing firms. Three major issues are explored: the differences between exporting and non‐exporting firms with regard to why they adopt AMT; the differences between exporting and non‐exporting firms with regard to how they adopt AMT; and the relationship between adopting AMT and exporting to global markets. Using multivariate analysis of variance (MANOVA), multiple comparison tests, pair‐wise comparisons, regression, correlation, and partial correlation analysis, the authors found that: exporting and non‐exporting firms adopt AMT for different reasons; exporting and non‐exporting firms adopt AMT in different ways; and there is a significant positive relationship between adopting AMT and exporting to global markets.

The purpose of this paper is to investigate how different manufacturing technologies are bundled together and how these bundles influence operations performance and, indirectly, business performance. With the emergence of Industry 4.0 (I4.0) technologies, manufacturing companies can use a wide variety of advanced manufacturing technologies (AMT) to build an efficient and effective production system. Nevertheless, the literature offers little guidance on how these technologies, including novel I4.0 technologies, should be combined in practice and how these combinations might have a different impact on performance.

Using a survey study of 165 manufacturing plants from 11 different countries, we use factor analysis to empirically derive three distinct manufacturing technology bundles and structural equation modeling to quantify their relationship with operations and business performance.

Our findings support an evolutionary rather than a revolutionary perspective. I4.0 technologies build on traditional manufacturing technologies and do not constitute a separate direction that would point towards a fundamental digital transformation of companies within our sample. Performance effects are rather weak: out of the three technology bundles identified, only “automation and robotization” have a positive influence on cost efficiency, while “base technologies” and “data-enabled technologies” do not offer a competitive advantage, neither in terms of cost nor in terms of differentiation. Furthermore, while the business performance impact is positive, it is quite weak, suggesting that financial returns on technology investments might require longer time periods.

Relying on a complementarity approach, our research offers a novel perspective on technology implementation in the I4.0 era by investigating novel and traditional manufacturing technologies together.