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This paper empirically examines the implementation pattern of different types of lean management (LM) techniques on the shop-floor. Based on the socio-technical systems framework, LM techniques are classified as social improvement tools and technical process standardization and stability practices. This categorization facilitates investigating their implementation relationship in a complex production system.

Based on the survey data from managers of the three major US auto-manufacturers and their suppliers (n = 137), measurement scales are developed using confirmatory factor analysis for the LM process improvement, stability, and standardization constructs. Hypotheses are tested by applying the Sobel test technique for mediating regression.

Statistical results confirm the mediation role of LM improvement tools between standardization and stability goal practices, indicating that technical process-oriented practices are not directly related and that their association is impacted by the corresponding implementation of social tools on the shop-floor.

The results indicate that LM practices should not be randomly implemented on the shop-floor but rather adopted and executed based on a systematic pattern. In LM systems, the implementation of process stability, standardization, and improvement practices on the shop-floor are more tightly integrated than traditionally assumed.

This study establishes a new categorization of specific LM tools based on social and technical characteristics. The conclusions highlight the importance of adopting a social emphasize of continuous improvement to establish a technical focus of process standardization and stability for LM implementation success.

This study empirically examines the effect of shop‐floor communication on implementation effectiveness of process management practices, and on the corresponding quality performance gained through process management implementation. It deals with four types of communication on the shop floor (small group problem solving, feedback, instructive communication, supervisory interaction facilitation) and three process management practices (process control, preventive maintenance, housekeeping).

Analysis of variance (ANOVA) and regression techniques were used to test the hypothesized relationships. Data were collected from 238 manufacturing plants through a questionnaire survey conducted in eight countries to develop reliable and valid measurement scales for operations management.

The statistical results demonstrate the positive effect of shop‐floor communication on the implementation of process management practices and the resultant quality performance. The results also suggest that each type of shop‐floor communication differently affects the way in which process management practices are implemented to influence quality performance.

Although the existing literature of quality management highlights the importance of communication and information management for the successful implementation of quality management, little detailed study has been conducted on how specific types of communication support quality management practices to obtain quality performance. This study contributes to the literature by breaking down communication into four types and providing specific empirical evidence on the relationship between each type of communication, process management practices, and quality performance.

This paper aims to investigate how manufacturers can foster insights and improvements from real-time data among shop-floor workers by developing organisational “learning-to-learn” capabilities based on both the lean- and action learning principle of learning through problem-solving. Second, the purpose is to extrapolate findings on how action learning can enable the complementarity between lean and industry 4.0.

An insider action research approach is adopted to investigate how manufacturers can enable their shop-floor workers to foster insights and improvements from real-time data at VELUX.

The findings report that enabling shop-floor workers to use real-time data consist of developing three consecutive organisational building blocks of learning-to-learn, learning-to-learn using real-time data and learning-to-learn generating real-time data − and helping others to learn (to learn).

First, the study contributes to theory and practice by demonstrating that a learning-to-learn capability is a core construct for manufacturers seeking to enable shop-floor workers to use real-time data-capturing systems to drive improvement. Second, the study outlines how lean and industry 4.0 complementarity can be enabled by action learning. Moreover, the study allows us to deduce six necessary conditions for enabling shop-floor workers to foster insights and improvements from real-time data.

The purpose of this paper is to investigate the application of key performance indicators (KPIs) on shop floor level in German small- and medium-sized enterprises (SMEs). The paper focuses on the examination of perception differences between shop floor employees and managers with regard to collection, calculation and consolidation of KPIs as well as visualization and motivational aspects.

To examine the hypothesis on differing perceptions regarding KPIs, 27 qualitative interviews with shop floor employees and production managers within 6 SMEs from the German machinery and equipment industry were conducted on basis of a semi-structured guideline.

The findings show that shop floor employees self-assess a lack of relevant knowledge when it comes to understanding KPIs. Moreover, the results show that shop floor employees perceive the visualization of shop floor KPIs as insufficient and non-motivational. This goes along with the finding that managers are aware of the lacking benefit of KPIs resulting from the rather negative perception of shop floor employees. The interviewed managers recognize a strong potential for improvement of their KPI systems.

The interview results confirm the need to design a performance management system on the shop floor that considers and aligns both management and operations, is directed to the shop floor level, considers explicitly the perspective of employees and integrates motivational elements.

The purpose of this paper is to develop and redefine the “classic” roles of shop floor management and quality control circles (QCCs) in Kaizen. In specific, it aims to examine the linkage between shop floor management and QCCs, and test the relationships among shop floor management, QCCs and long-term Kaizen improvement outcomes.

This study employs qualitative method by using a questionnaire to obtain data from 371 respondents in nine Sino-Japanese automotive joint-ventures. The data are analysed with the method of canonical correlation approach.

The study identifies important factors to assist the adoption of shop floor management and QCCs for Kaizen. The analysis on the survey indicates that not all the shop floor management tools could help to identify improvement opportunities. QCCs are effective in addressing large problems and challenging current policies in companies, however, they have low impacts on individual learning.

The data of this study come from nine Sino-Japanese automotive joint ventures. Therefore, the sample selection is limited to these companies. The findings are able to be applied for improving the similar problems which were identified in this study.

The study has the following practical implications, first is small shop floor problems can be identified and solved rapidly and continuously at source by shop floor management. The second one is QCCs, or other similar group-based improvement approaches take long to be fully addressed and implemented. Third, practical solutions can be achieved from small and gradual changes, and they can prevent the results backsliding to the pre-improvement stage. Finally, QCCs are hardly to achieve a better improvement alone. It requires other Kaizen approaches to support.

This study is probably the first to explore and investigate the implementation of the four building block tools of shop floor management in real business practise, and more specific the first to discuss the relationship among shop floor management, QCCs and long-term improvement outcomes based on empirical data from Sino-Japanese automotive joint-ventures.

This chapter provides an extensive review of literature on the interaction between and interdependence of informal and formal working practices in various workplace settings. The aim of the chapter is to elucidate the organisational, managerial, human relations and social factors that give rise to informal work practices and strategies, on the shop-floor not only at workers and work group levels but also at supervisory and managerial levels. This chapter helps the reader to understand the informal work practice of making a plan (planisa) in a deep-level mining workplace.

The purpose of this paper is to revisit discussions on managerial work, seeking to re-examine the front-line service manager’s position within the service triangle, and bring forward questions of agency that remain under-developed by scholars. Challenging the assumed unitarist and “consensus” standing point in organizations it recognizes that front-line managers, similarly to their subordinates, resist corporate demands and unveils stories of “battles” and disengagement towards their role, providing a rich empirical agenda regarding managerial misbehaviour. In order to explore front-line managers’ agency issues, the paper adopts the framework of the dimensions of misbehaviour, as developed by Ackroyd and Thompson (1999), to capture and to better describe and understand the recalcitrant agential practices by front-line managers.

The paper calls on qualitative data from two case study organizations in the Cyprus food-retail sector. In total, 46 interviews took place with participants across different departments and different management levels. This aimed for a better and deeper understanding of the research problem through understanding of the different perspectives.

The evidence reveals the intensification of FLSMs’ work and their feelings of pressure. FLSMs, however, did not stay apathetic and have utilized tactics to oppose the increasing workload and the expansion of their role. The paper classifies these tactics using the four dimensions of misbehaviour (Ackroyd and Thompson, 1999), namely, appropriation of time; work, product and identity. It shows that FLSMs not only resist corporate demands, like their subordinates, but also devised practices which are similar to workers. The data also reveal a variety in actions of misbehaviour between FLSMs depending on the level of customer interaction and their mobility on the shop floor.

Students of managerial work overlooked the political realities of management and the contested nature of (front-line service) management work. As this study has shown FLSMs across the shop floor strongly identify more with “front-line employees” than senior management, protecting their own interests within the employment relationship via oppositional actions and disengagement. FLSM is, of course, in an agency relationship with capital; however, this neglects the heterogeneity in interests at different levels of management. This paper shifts the focus of management research away from the traditional agency argument and discusses FLSMs as “misbehaving agents”. It challenges the assumed unitarist and “consensus” standing point for FLSMs in organizations and calls HRM scholars to embrace a pluralist analysis in line management research.

This research shows that FLSMs misbehave as an expression of discontent towards the expansion and intensification of their role. Yet, the data reveal variation in the organization of FLSMs’ work across the shop floor and consequently variation in their actions of misbehaviour. This suggests that it is erroneous to presume a similar labour process for these managers and/or over-generalize their battling actions. HR practitioners will need to re-examine the roles of FLSMs in organizations, recognize the variety of interests within management, step away from rhetoric discourses of unproblematic devolvement of HR and managerial tasks to the front-line and appropriately review, redesign and re-organize front-line managerial work.

Although research has fruitfully located the powerlessness of front-line managers as a central theme in their analysis, the complexity of the front-line management position within the social relations of interactive service work and their “logic of action” within their labour process remains a relatively marginal theme in research. Indeed, FLSMs’ position within the triangle, where managerial work is subject to degradation and trilateral conflicting dynamics and their battles within their own labour process, still remains under-explored. This study addresses this research lacuna focusing on the FLSMs’ experiences on the front-end and their actions of misbehaviour within their labour process.

The paper brings forward questions of agency that remain under-developed by scholars and unveils “stories of battles”. It discusses FLSMs as “misbehaving agents” a question that is only superficially addressed in resistance and managerial studies. This paper challenges the embedded HRM unitarist assumption that FLSMs are conscientiously agents of the capital and reveals evidence suggesting the plurality of interests across management. HRM scholars, especially those discussed line managers as HRM partners, have overestimated FLSMs’ identification with senior management and the strategic goals of the organization. As this study has shown FLSMs across the shop floor strongly identify with “front-line employees”, protecting their own interests within the employment relationship via oppositional actions and disengagement.

Many studies have found that Lean practices provide better performance in a stable business environment. However, there is limited information on how Lean practices influence performance gains (defined in this paper as improvement and sustenance of performance) in an uncertain (complex and dynamic) environment. This study aims to investigate how the implementation of Lean helps to sustain performance in such context.

The study draws on an in-depth investigation of two capital goods manufacturing engineer-to-order (ETO) cases, in which performance sustenance is discussed in relation to the extent, locus and extensiveness of implemented Lean practice bundles.

Findings indicate that a higher extent of Lean practices’ implementation, covering both shop floor and transactional processes, increases the possibility of performance sustenance in ETO. Furthermore, a coherent approach in the pre-, during- and post-implementation phases of the Lean change process is required to foster performance sustenance. Lean practices in ETO are modified to suit context change from repetitive manufacturing.

This study proposes performance sustenance as a performance measure in a highly uncertain context, such as ETO, as a single reference cannot effectively measure performance improvements over diverse orders. From this perspective, appropriate Lean implementation contributes towards building capabilities for flexibly and proactively managing uncertain circumstances.

Even companies operating in highly uncertain (complex and dynamic) contexts may benefit from significant performance gains, thanks to the Lean implementation. This can be achieved by a balanced implementation of practices at shop floor and transactional processes, and their mindful customisations.

The study compares Lean implementation in ETO with that of high-volume–low-variety systems established in the literature. It qualitatively discusses how Lean implementation as an overarching effort both in shop floor and transactional processes leads to better sustenance of achieved performance improvements in shop floor under high uncertainty.

The purpose of this paper is to investigate design features of variable pay plans adopted for shop-floor workers engaged in manufacturing firms that had implemented lean production systems, and the effects of design features on their job performance.

In total, 892 shop-floor workers attached to lean implemented manufacturing firms in Sri Lanka responded for the study. Structural equation modelling was used for the data analysis.

It was found that the performance evaluation-base for variable payments, variable pay calculation-base and goal setting for variable pay significantly predict job performance of the shop-floor workers.

It could be expected that the academics and practitioners alike are motivated by their desire to clearly apprehend the contribution of variable pay plans on job performance of the shop-floor workers engaged in lean production systems. This demands more investigations to better understand the design features of variable pay plans.

The purpose of this paper is to use an inter-disciplinary approach to examine the relevance of F.W. Taylor’s principles to modern shop-floor practices in the context of a manufacturing organization.

Standard time study guidelines laid out by the ILO were adopted and random observations made between two operators independently performing an identical operation in the shop-floor premises of a particular factory.

It was evident from the study that modern management has developed the science for each element of the operator’s manual work, as postulated and proposed by F.W. Taylor. It was also evident that completion of the operation on time was necessary for the operators but not as important as the total number of jobs performed during the duration of the shift. These empirical findings highlighted the high relevance of F.W. Taylor’s principles to modern shop-floor practices.

The authors adopted time study observation as the single method to collect real data from real practices but this could be considered as a biased approach. Since the time study observation is a slow, time consuming, and expensive process of obtaining data, the authors restricted the study to only two operators. Further, the study was carried out in a real setting under several assumptions that may limit its wider applications and practical implications. The study findings suggest that measuring the operator’s performance in terms of time consumption and resource utilization is necessary but not sufficient to evaluate and improve his/her productivity because operators evaluate their performance in terms of the total number of jobs completed during the duration of the shift. Therefore, it is suggested that the managers on the modern shop-floor measure the output at the aggregate level for the given input, while developing new work methods as well as devising performance management and reward systems.

The study has contributed to the body of knowledge by conducting a complete assessment of F.W. Taylor’s first principle from its origin to its application in modern shop-floor practices. Also, the authors empirically examined the relevance of Taylor’s principles to modern shop-floor practices in the context of a manufacturing organization. The study supports the descriptive work of Freeman (1996), who envisaged the relevance of Taylor’s ideas to modern management practices; also, it gives a few directions to test behavioral operations theory in terms of using real operational data to examine an established organization theory (Gino and Pisano, 2008).