Japanese production management: An evolution—With mixed success

Abstract Japanese production management (JPM) became a dominant influence in the field of operations management when, in the early 1980s, knowledge of its main elements became known beyond Japan. Those elements – quick set-up, small lots, cells, kanban, and so on – are well known. Rather than explaining them again, this paper's objective is to explore the sequence of events leading to JPM as a competitive force globally, as well as its impact on theory and practices in operations management. JPM's evolution includes shifting terminologies, fusions and adulterations; limited extensions from manufacturing into services and innovative enhancements, largely of Western origin. Longitudinal research data, based on inventory trends, provide insights on JPM's diffusions and its uneven results. Latter-day puzzling lapses and disappointments, among Japanese as well as Western companies, raise questions about JPM's sustainability, as well as some of its changing manifestations. While the core of Japanese production management, now over three decades old, appears to have become solidly mainstream, its current and future states are problematic.

[1]  Joseph Moses Juran Juran on planning for quality , 1988 .

[2]  田口 玄一,et al.  On-line quality control during production , 1981 .

[3]  I. Winfield Japanese manufacturing techniques , 1994 .

[4]  Philip B. Crosby,et al.  Quality Is Free: The Art of Making Quality Certain , 1979 .

[5]  M. Walton The Deming management method , 1986 .

[6]  Geoffrey Boothroyd,et al.  Product design for manufacture and assembly , 1994, Comput. Aided Des..

[7]  D. Elizur Quality Circles and Quality of Work Life , 1990 .

[8]  F. Leonard,et al.  The Incline of Quality , 1982 .

[9]  J. Burnham Japanese productivity : a study mission report , 1983 .

[10]  Armand V. Feigenbaum,et al.  Total quality control , 1961 .

[11]  Peter M. Senge,et al.  Bookshelf - High Output Management, Built to Last: Successful Habits of Visionary Companies, The Fifth Discipline: The Art & Practice of the Learning Organization , 2006, IEEE Softw..

[12]  K. Ishikawa What is total quality control the japanese way , 2002 .

[13]  Richard J. Schonberger,et al.  World Class Manufacturing Casebook: Implementing Jit and Tqc , 1987 .

[14]  Carol Jean McNair,et al.  Meeting the Technology Challenge: Cost Accounting in a Jit Environment , 1988 .

[15]  Richard Schonberger,et al.  World class manufacturing : the lessons of simplicity applied , 1986 .

[16]  Stephen P. Bradley,et al.  Wal-Mart Stores in 2003 , 2003 .

[17]  J. Hackman,et al.  Total Quality Management: Empirical, Conceptual, and Practical Issues , 1995 .

[18]  Kenneth K. Boyer,et al.  COMPETITIVE PRIORITIES: INVESTIGATING THE NEED FOR TRADE‐OFFS IN OPERATIONS STRATEGY , 2002 .

[19]  Edward J. Hay The just-in-time breakthrough : implementing the new manufacturing basics , 1988 .

[20]  赤尾 洋二,et al.  QFD : the customer-driven approach to quality planning and deployment , 1994 .

[21]  Edward M. Knod,et al.  Operations management : meeting customers' demands , 2001 .

[22]  R. Schonberger Japanese manufacturing techniques : nine hidden lessons simplicity , 1982 .

[23]  M. Schniederjans Topics in just-in-time management , 1992 .

[24]  Jennifer L. Hartnett,et al.  Managing Quality: The Strategic and Competitive Edge , 1988 .

[25]  Mario T. Tabucanon,et al.  Decision models for industrial systems engineers and managers , 1980 .

[26]  G. D. Galsworth,et al.  Visual systems : harnessing the power of the visual workplace , 1997 .

[27]  Richard Tanner Pascale,et al.  The art of Japanese management : applications for American executives , 1981 .

[28]  John B. Groocock The Chain of Quality: Market Dominance Through Product Superiority , 1986 .

[29]  Mark L. Dean,et al.  MALCOLM BALDRIGE NATIONAL QUALITY AWARD: Does Baldrige Make A Business Case for Quality? , 2004 .

[30]  R. Cooper How Cost Accounting Distorts Product Costs , 1988 .

[31]  W. Ouchi,et al.  Theory Z: How American Business Can Meet the Japanese Challenge. , 1981 .

[32]  Barbara B. Flynn,et al.  An exploratory study of the nature of cumulative capabilities , 2004 .

[33]  Sud Ingle Quality circles master guide : increasing productivity with people power / Sud Ingle , 1982 .

[34]  Michael Hammer,et al.  Reengineering Work: Don’t Automate, Obliterate , 1990 .

[35]  Richard T. Pascale,et al.  Zen and the Art of Management. , 1978 .

[36]  Akira Takeishi,et al.  Modularization in the Auto Industry: Interlinked Multiple Hierarchies of Product, Production, and Supplier Systems , 2001 .

[37]  James Cammarano Lessons to Be Learned Just in Time , 1997 .

[38]  Phillip S. Mitchell Japanese Manufacturing Techniques: Nine Hidden Lessons in Simplicity , 1983 .

[39]  Y. Sugimori,et al.  Toyota production system and Kanban system Materialization of just-in-time and respect-for-human system , 1977 .

[40]  Daniel T. Jones,et al.  The machine that changed the world : based on the Massachusetts Institute of Technology 5-million dollar 5-year study on the future of the automobile , 1990 .