Learning Lean: Rhythm of Production and the Pace of Lean Implementation

International Journal of Operations and Production Management, Forthcoming

Georgetown McDonough School of Business Research Paper No. 3765494

41 Pages Posted: 18 Feb 2021

See all articles by Torbjørn Netland

Torbjørn Netland

ETH Zürich - Department of Management, Technology, and Economics (D-MTEC)

Jason D. Schloetzer

Georgetown University - Department of Accounting and Business Law

K. Ferdows

Georgetown University - Department of Decision Sciences, Information Sciences & POM

Date Written: January 2021

Abstract

Purpose: Why some assembly factories implement a lean program faster than others is an enduring puzzle. We examine the effect of a fundamental characteristic of every assembly factory—its rhythm of production.

Approach: We designed a multi-method study and collected data from a leading global equipment manufacturer that launched a lean program across its factory network. We use quantitative data gathered from internal company documents to test our hypothesis that production rhythm affects the pace of lean implementation. We then analyze qualitative data from interviews and factory visits to derive theoretical explanations for how production rhythm affects lean implementation.

Findings: Consistent with our hypothesis, we present evidence that factories with faster production rhythms implement lean faster than those with slower rhythms. This evidence is consistent with learning theories as well as the literature on organizational routines and forms of knowledge. We propose a theory of the relation between rhythm and learning in lean implementation.

Research implications: The hitherto unexplored relation between production rhythm and lean implementation raises intriguing questions for scholars and ushers new insights into how organizations learn to implement lean.

Practical implications: Organizations need to calibrate their expectations for lean implementation pace when their factories have widely different production rhythms and find ways to mitigate any adverse effects slower rhythms may have. Organizations can alleviate the unfavorable context of slower rhythms by inculcating practices in the factory that emulate the learning environment present in faster-paced factories.

Originality: We contribute novel quantitative and qualitative evidence that production rhythm affects lean implementation through learning-based mechanisms.

Keywords: Lean, Operational excellence, Organizational learning, Production rhythm, Takt time, Multi-method design

Suggested Citation

Netland, Torbjorn and Schloetzer, Jason D. and Ferdows, K., Learning Lean: Rhythm of Production and the Pace of Lean Implementation (January 2021). International Journal of Operations and Production Management, Forthcoming, Georgetown McDonough School of Business Research Paper No. 3765494, Available at SSRN: https://ssrn.com/abstract=3765494

Torbjorn Netland

ETH Zürich - Department of Management, Technology, and Economics (D-MTEC) ( email )

ETH-Zentrum
Zurich, CH-8092
United States

Jason D. Schloetzer (Contact Author)

Georgetown University - Department of Accounting and Business Law ( email )

McDonough School of Business
Washington, DC 20057
United States

K. Ferdows

Georgetown University - Department of Decision Sciences, Information Sciences & POM ( email )

Washington, DC 20057
United States

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