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Abstract
Manufacturing technology developments need to be aligned with business
needs. A U K government scheme to facilitate this linkage was carried out by
contracted consultants in a series of companies. The initial task was to
conduct a market needs review, so that the appropriate manufacturing
developments to support those needs could be made. The authors 'shadowed'
several of these company initiatives, and four typical cases are described to
illustrate the type of work done by consultants in such situations. In each
case different types of inadequacy made it difficult to link the market review
to technology development needs. These types of inadequacy are discussed,
and some possible explanations are suggested. © 1997 Elsevier Science Ltd
ascertain. The cases are then discussed in terms of • prescriptive steps for selecting the appropriate
some general features common to each which show AMT;
why they have not achieved the strategy aims of the • technology management issues (including IT
MPI scheme. The opportunity to conduct the research issues);
arose out of a UK government scheme to which a • benefits claimed for AMT, and the degree to which
later section gives the background. they are realised in practice;
• organisational aspects of AMT;
• financial justification of AMT;
• methodologies for successful implementation.
2, MANUFACTURINGSTRATEGYANDAMT SOME
ASPECTSOFTHELITERATURE The principal findings, at least for the purposes of the
present study, concern selection and implementation
Manufacturing strategy is concerned with the align-
of AMT:
ment of a firm's productive resources and technology
with its strategic goals. Beginning with two seminal
• AMT initiatives often fail, commonly through
articles by Skinner (1969, 1974), the field developed
implementation difficulties (Meredith, 1987a,b;
to the point where an article by Voss (1995) could
Babbar and Rai, 1990);
look back over more than thirty years of publications
• these initiatives are among the longest, most com-
and compare alternative paradigms of manufacturing
plex and expensive developments a firm can under-
strategy. The effect of all this scholarly activity on
take (Meredith, 1987b);
manufacturing practice is less certain: Skinner (1992)
• even when implemented, AMTs may not deliver
himself reflected that "the a d o p t i o n . . , in industry has
all that was expected, especially if the market place
been quite modest. Very few firms have a manufac-
changes during a lengthy implementation period
turing strategy". This is bome out specifically in the
(Boer et al., 1990);
UK by research carried out at Cranfield School of
• strategic considerations are critical to success; if
Management which in "50 per cent of the business
the initial strategic analysis is faulty or omitted, the
units studied" found evidence of "poor strategic
likelihood of failure is high (Voss, 1986; Badiru,
vision for manufacturing operations" (Sweeney,
1990).
1994). Our research, as will be seen, corroborates
these views and suggests at least one reason for the
This present study aims to contribute to this area
deficiency in UK companies' strategic development.
of knowledge by looking at the crucial early phase of
Analysis, of course, requires a general technique or
AMT developments, the market analysis, which is the
framework which can be applied to an individual
key to formulating strategically oriented manufactur-
case, and the manufacturing strategy literature sug-
ing developments. The nature of the contribution is
gests several of these. For the MPI scheme it was
unusual (if not quite unique) in looking in detail at a
important that client companies and their consultant
particular phase, in being grounded in multiple case
advisers used a tool which enabled them to prioritise
studies, and in its focus on the effectiveness of con-
investments in manufacturing according to the needs
sultants' contributions. The role of the consultant in
of the company's markets. One tool for such prioritis-
this field, as the literature surveys (Chen and Small,
ation is the identification of order winners and quali-
1996; Sambasivarao and Deshmukh, 1995) mentioned
fiers, at a detailed level of segmentation, often at the
earlier suggest, has been relatively little studied.
customer/product line level (Hill, 1993).
companies with less than 500 employees. One hun- gle research theme and the quality of access to all
dred and forty small and medium-sized enterprises relevant data.
(SMEs) have taken part in this scheme, which was
completed in December 1994. The AC role was to analyse the methods used by
consultants to fulfil the aims of the scheme. This
The MPI scheme was primarily concerned with the involved an investigation of the
enhancement of the ability of a firm's manufacturing
function to support agreed markets, as clearly indi- • process and content of market reviews;
cated by the stated intent of the initial DTI announce- • degree of linkage between market review and the
ment. In this statement it stated the aim of the scheme recommended AMTs;
was to: • nature and impact of the AMTs.
"enhance advanced manufacturing technology Because the reviews were conducted in the same
(AMT) activities within consultancy, industrial, structured way at each site, cross-site comparisons
research and training communities in the UK by and some generalisations are possible, allowing for
encouraging SMEs to adapt best practice in their the different context of each firm.
application of AMTs by strategically planning
and implementing AMTs for competitive advan-
tage". 4. THE CASESTUDIES
Each project had two major parts; the market review, It is clear from the above that the analysis of the
and the selection of appropriate AMTs. The first of market is fundamental to the MPI scheme and to the
these parts was explicitly emphasised in the guide- successful identification of appropriate technology
lines issued to advisers: developments. Without a sufficiently detailed under-
standing of the difference between the needs of differ-
"the key to any project is the analysis phase ent segments, or even different customers, it will be
which challenges a company's assumptions difficult to establish precisely how a company can win
regarding its business, markets, competitors and orders from competitors, or even retain its existing
why products are chosen by customers customer base. This means an in-depth analysis, pro-
viding sufficient detail to differentiate customers' pro-
the market review phase is vital because it gives ducts and past, present and likely future scenarios.
context to the relevance of any changes to or The following examples each show, in different ways,
reviews of existing capabilities how the failure to provide such a market review
a project must link the company's competitive inhibited a firm's ability to link its market needs with
approach in its market to its capability to provide the AMT initiatives they undertook.
goods which meet market needs".
4.1 Company A
A unique feature of the scheme was the inclusion
of an analytical co-ordination (AC) role, undertaken This company makes personnel protection pro-
by a group of operations management academics ducts. The consultants advising the company under-
whose task was to analyse the methods used by con- took the market analysis required by the MPI scheme,
sultants working with client companies to meet the and the resultant document was described as a 'brief
aims of the scheme. The AC team has undertaken a business review' and contained general statements on
structured review of fifty of these projects, for which the firm's image, market size, the firm's market share
they were permitted, as a condition of any MPI grant, and competitors. In reviewing current production, it
full access to all personnel involved and all relevant is noted that 700 product lines are held in inventory
data and documents. The project reviews all involved: and that order lead time is typically three weeks, with
80% deliveries on time. The organisation of market-
• several site visits; ing and sales departments is also described.
• in-depth comparative analysis of documents;
• structured discussions with company executives Key factors concerning this review and the method-
and consulting advisers; ology used by the consultants include:
• additional analyses of primary data.
(i) the consultant specialising in market analysis
This task therefore offered a unique research opport- spent only 2% of the total project time;
unity, because of the number of projects within a sin- (ii) the lead consultant also spent time on market
TedmvaSonVol.17No.3 111
T. Hill and R. Westbrook
analysis but, given the completion date of this • the group members then prioritised the eight categ-
phase, he could only have spent, at best, a ories as shown in Table 1.
further 9% of the total project time even if he
had concentrated solely on this activity during
this phase of the project; 4.1.1 Comments
(iii) the consultants based much of their review on
a report completed nine months earlier by a
• No insights into the market were provided. Hence,
different consultancy company;
market orientation was not part of either the gener-
(iv) there was no contact made between these two
ation of improvement suggestions or their prioritis-
groups of consultants to discuss the findings
ation within the TQM activity.
of the first report;
• Eventual prioritisation of actions to follow was by
(v) the first report highlighted different segments
overall category and not by individual suggestion.
in the company's markets; the second report
reviewed the market as a whole;
(vi) the second report concluded that the company
wins orders from all distributors and end users 4.2 Company B
on the basis of the same criteria and within the Company B manufactures shop refurbishment and
same given priority: "product quality, service, materials handling equipment. A fairly substantial
then price". market review was undertaken by their consultant
advisers, involving 25 man-days (14% of total project
The next step in the approach followed by the con- time) and three reports. The contents included:
sultants was to identify several key areas to address
or objectives to follow. The areas covered were: • size and structure of the UK retailing market;
• sales of shop and office fittings in the UK;
• the firm should aim for 30% total market share; • analysis of 1 l major competitors, showing financial
• stronger relationships with fewer suppliers should position and customers served.
be developed;
• moulded parts currently bought out should be Fifteen prospective customers were asked for their
manufactured in-house; views on Company B's and eleven competitors'
• pursue a policy of zero defects; strengths and weaknesses. The results are presented
• improve delivery performance; in Table 2 (marks out of 10, average response).
• reduce costs.
4.2.1 Comments
In support of its overall desire to improve, the com-
pany also undertook two major AMTs: • The survey covered only the shop refurbishment
sector.
(a) the in-house moulding of components, leading to • The consultants pre-listed the criteria to be review-
an estimated 40% reduction in cost as well as ed.
benefits from shorter lead times, fewer defects • The shop refurbishment sector was assumed to be
and lower inventory; the same.
(b) operational improvements based on a TQM • Results were presented as an overall statement.
initiative.
TABLE 1. Company A: categories and their priorities
1,12 Tedmv,,'dJonVol.17No.3
Linkingtechnologicalinnovationsto sb'ategic needs
TABLE 2. Customer survey for Company B and a strong and a weak competi- Only with these insights was manufacturing able to
tor
recognise the key market needs and develop its
Factor Company B Competitor
response in terms of both IT and production process.
Strong Weak
4.3 CompanyC
proposal speed 8 9 7 Company C makes powder coatings, mostly for the
proposal quality 7 7 7
standard product 8 7 8
UK market. Its market review occupied much less
non-standard product 8 9 7 consulting effort than company B's, only five man-
delivery speed 7 8 7 days or 6% of total project time. The review, based
sitework 8 8 7
personnel 9 9 7
on interviews with two suppliers and six customers,
flexibility 8 8 7 produced the following outcomes:
value for money 8 8 7
The manufacturing initiative focused on revising Again, this data did not influence the technology
the factory layout into cells, and installing a new IT choices. Rather a separate 'technology review' was
system for manufacturing planning and control. conducted before the market review results were
Together these improvements permitted the company available (see Table 3). This technology review is a
to improve its delivery speed and reliability during 12-page report with details of the productivity impact
1993. One major supermarket chain remarked that, of colour changes and the cost and delivery perform-
had this improvement not occurred, it would have ance impact of the 15% reject rate. It also contained:
removed all its business from company B.
• a review of the technical capabilities of company
The company's performance during this phase of C's existing powder coating equipment:
the MPI deteriorated to the point where it was taken • a list of changes in technology with estimates of
over by a competitor. At this point consultancy sup- new equipment costs;
port was terminated. Given the new position and its • a list of eight recommended technical improve-
perilous nature, the company was forced into dis- ments for the company.
cussions with its major customers. This identified
that: TABLE 3. Company C: consultants' hours for weeks 5-10 (source: consulting
firm's invoices)
TechnovationVd. 17 No. 3
T. Hill and R. West.brook
A similar list was provided for the electroplating part 1991. The MPI consultants claimed they would take
of company C's business. advantage of this to build on the earlier studies. In
their project proposal they undertook to "extract from
Neither the marketing nor the technology review the exising . . . analysis the order winning criteria",
bore much relation to each other. Indeed, not only and in a supporting letter promised to "review this
did the market review not influence the AMT choices work and build on it". The new effort took nine days
because it was once again too general, but the prin- and led to a sixteen-page report, with the following
ciple that there should be such a link was not recog- areas of analysis:
nised. Company C has, however, taken the project
further, with initiatives on the following: • size of UK market (volume and value)
•- by product group (indicates growing or
(a) Further customer surveys are to be regularly declining),
undertaken, as part of a TQM initiative. Ironi- - - by equipment specifier;
cally, the survey document asks customers to • buying criteria, ranked within the two main pro-
indicate and rank order-winning and order-quali- duct groups;
fying criteria: i.e., the company subsequently • company D's sales and market share by product
seeks to obtain the key data it needed before group;
(though it still does not distinguish between pro- • customer perceptions of company D;
duct groups). • requirements for success of the new standard pro-
(b) Business process groups (BPGs) have been estab- duct range - - company D's own views plus six
lished to review processes from quotation to questions for them.
invoicing.
(c) An IT system has been specified to cover: The substantive part of all this from an MPI scheme
• sales order entry and invoicing; standpoint, the buying criteria and customer percep-
• nominal ledger and sales ledger; tions, are reproduced from one of the earlier studies.
• management accounts and payroll. The consultant accepted the limitations of the earlier
study, which confined analysis to the UK, and did not
segment in any more detail than product groups. In
4.3.1 Comments attempting to make a link from buying criteria to
AMT intiatives, two pages of a subsequent report did
make one change to the earlier (pre-MPI) list: it elev-
• The market review took one man-week, only 6%
ated price to the key criterion and thus proposed that
of total consulting time.
change efforts should focus on "cost reduction", then
• Only six customers and two suppliers were inter-
"shorter, more reliable deliveries". There was no
viewed.
analysis of price sensitivity by customer or product.
• Markets were treated as homogeneous.
• The technology review activity overlapped the
In fact this company has gone on, in 1994, to make
market review work, and had no relation to it.
radical and impressive changes in manufacturing,
• No link was made from the market analysis to
with demonstrable gains in inventory management
AMT developments. Instead, the company has pur-
and productivity, through a cellular/Kanban approach.
sued initiatives related to efficiency and manage-
ment control. However, the link to the MPI scheme is tenuous at
best, since none of the changes came out of the con-
sultants' reviews and no outside help has been used
in implementation. The virtue of the scheme for this
4.4 Company D company has been in providing a catalyst for change
and an opportunity to introduce new management into
Company D manufactures air conditioning equip- key roles.
ment, ranging from extremely large, complex, highly
customised close control systems to small, fairly stan-
4.4.1 Comments
dardised systems. At the time of the MPI project,
company D also introduced a new standard product
intended to be sold from stock. Half the company's • The market review took nine days only (8% of total
sales are for export. project time).
• Analysis was confined to the UK market although
The MPI project began in 1992, but two earlier half of the sales are for export.
market reviews had been carried out in 1990 and • No segmentation beyond product groups.
114 Tedmova'den¥01.17No.3
Linking technological innovationsto strategic needs
• Earlier analysis by another consulting firm was competitive environment this implies a very thorough
accepted but not checked or developed. investigation, which makes use of many sources of
• Price was elevated as the key order-winner, with information. But in the cases cited above the most
little analytical justification. common source of information was existing cus-
• No link to AMT developments. tomers. Potential or former customers, whose view
may be more valuable in understanding why orders
are lost, are not surveyed. Even with existing cus-
tomers, the whole story will often only emerge when
5. DISCUSSION checked with internal sources, for a company and its
customers usually have a joint history which needs to
These four case studies demonstrate the difficulty be understood when interpreting customer responses.
companies of this type are experiencing in obtaining Too often existing customers have been the sole
an understanding of markets which permits AMT source of information and, as we have seen in two
decisions to be demonstrably strategic. They also cases, earlier studies are taken at face value.
exhibit, to differing degrees, several features of many
of the MPI projects, which partially explains this dif- To provide the kind of insight required, a market
ficulty. These features can be grouped as follows: review needs to provide the kind of detail which is
meaningful at the manufacturing process level. The
(1) the understanding of strategic thought; tendency to restrict analysis to broad market segments
(2) the aim and content of a market review; or product groups is more characteristic of a market-
(3) the nature of a strategic link from market to ing review than a market needs investigation. The
AMT. product groupings which are used in the sales and
marketing functions may not be those which the
We discuss each of these in turn. manufacturing function finds significant. All the mar-
ket reviews are too broad in their segmentation to per-
5.1 The understandingof strategic thought mit precise technology-related questions to be asked,
let alone answered.
We suggested at the outset that strategy could be
considered at three levels: the corporation, the busi- Similarly, there is a tendency to regard all orders,
ness unit, and individual functions. In each of the large or small, standard or special, one-off or repeat,
cases we have described, and in many others not used for immediate delivery or with plenty of notice, as
here, these levels are consistently mixed up. The 'sales'. Yet the manufacturing function will regard
information on market size and growth or decline of these as very different in terms of the demand placed
sectors is very relevant to corporate strategy, but too upon it. The trends at this level of detail are likely to
broad to enlighten the business unit already largely be important in making future technology choices.
committed to its markets. Yet most reports begin with This is internal data, which is relatively easy to obtain
this data, and not only by way of preamble - - time and analyse; however, without an appropriate frame-
and money are devoted to it, as our analysis of con- work that requires such investigation, such evidence
sultants' time sheets consistently shows. will be overlooked, as happened in all four cases
above.
There is also a lack of strategic frameworks to
guide or illuminate the investigations. In these cases
'strengths and weaknesses' (one half of SWOT 5.3 The nature of a strategic link from market to AMT
analysis) and competitor analysis are the only frame- This feature follows from the preceding two. With-
works used; but even the latter is restricted, in three out an understanding of strategic thinking, and with
of the four cases, to a listing of the main competitors a market review that is consequently too aggregate,
and the market share they enjoy. Only in company C it will be impossible to demonstrate that meeting the
does the analysis get beyond this level and look at needs of target markets requires certain precise AMT
industry best practice and the strengths and weak- investments to be made. But there is some evidence
nesses of major competitors. that the n a t u r e of such a link is little understood.
Thus, although 'order-winning' (or 'buying') criteria
5.2 The aim and content of a market review appear in two of the four cases, in neither are they
followed through into technology specifications. In
The aim of a market review in the MPI scheme is the case of company C, where they are to be used
to provide insight into what is required to compete in in follow-up customer surveys, the criteria listed are
a company's target markets. For an SME in a very chosen by the company and assumed to be the same
for all product groups. In the case of company D also, MPI scheme to implement the view. He persuades
although the 'buying criteria' are part of the market the consultant of this view which the consultant
review, that review is in terms too broad to permit feels hired to implement.
those criteria to be translated into anything more (5) The client and consultant have already entered
specific than a general, plant-wide, effort for cost into a relationship, and continue with it under the
reduction. This may in itself be beneficial, as com- MPI scheme conditions.
pany D has found, hut one cannot be confident that (6) An existing report is assumed to meet the con-
the investment was the most strategically relevant for ditions of the scheme (see company D above).
the most profitable target markets. (7) Neither client nor consultant agree with the fun-
damental premise of the scheme, i.e. that AMTs
In the absence of specific, strategically oriented must be strategically oriented, which requires a
innovations, there is a tendency to fall back on gen- detailed market analysis.
eral developments likely to have impact in various
areas (such as TQM), or efficiency and control
enhancement which will lead to immediately measur- Each of these possible explanations has some anec-
able improvements likely to justify a consultant's dotal support from the cases analysed thus far. Which
fees. Good as that may be, it may also be an opport- of them dominates, and why, would require a separate
unity missed. Without an in-depth, strategically- study. For the purposes of this paper, though, it seems
oriented market analysis linked closely to AMT fair to conclude that:
developments, the company cannot know.
116 TedmvalkmYol.17No.3
Linking technological innovationsto strategic needs