Lean management as a countermeasure for “Normal” disruptions

The academic and practitioner literature offer numerous examples of firms that have achieved significant performance improvement as a result of implementing lean management. Lean firms consistently apply well-defined tools and the relationship between implementation of these tools and improved performance is well-established in the literature. Many lean practices, such as standardized work and visual cues, reduce variability, increase productivity, and make problems more visible which can create a culture where disruptions occur less often. Although there is evidence that lean implementation leads to reduced disruptions, a question that remains unresolved is why these lean management tools lead to fewer disruptions and whether conditions such as the level of complexity and inventory in the system predict the successful application of these lean practices. Because many of the firms that adopt lean management can be characterized as complex work systems, we draw insights from literature on complex organizations operating in environments that are inherently perilous. Two constructs that are addressed in this literature are fundamental to the concept of lean management – interactive complexity and tight coupling or organizational slack. We argue that theory that applies to complex organizations provides a lens for viewing how lean management firms avoid disruptions and conclude that the theoretical basis for lean management lies in understanding how to overcome the complexity inherent in these systems to achieve disruption-free performance.