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In the early eighties, when awareness of the microelectronics
revolution was at its peak and debates raged alternately heralding
its promises and fearing its threats, Ingersoll Engineers came
up with a set of surprising results from a survey of British manufacturing.
When assessing the risk of investment in automated technologies
their results showed an inverse relationship between the level
of automation and the likelihood of achieving increased productivity.
In fact, they found only an 18% rate of success in firms that
went for the "high technology" option, in contrast with an 84%
success rate in firms that focused mainly on reorganization, introducing
only a few selected changes in equipment (See Fig.3).
Rather
than conclude that computer integration and flexible manufacturing
systems (FMS) cannot yield expected results, what Ingersoll argued
is that organizational change is a precondition for reaping the
potential benefits offered by the new equipment. They also found
that there is considerable leeway to improve production processes
through organizational change that can be undertaken before any
new equipment is incorporated. In some of the cases they studied
as much as 80% of the initial improvements in productivity could
be attributed to reorganization alone[10]
.
These
findings are in line with the increasingly accepted explanation
of the productivity paradox in the OECD countries. At a time when
investment in modern equipment was growing rapidly and new technologies
had been widely applied, instead of the expected increase in efficiency
there was a decline in the rate of productivity growth in these
economies. The TEP Report locates the main causes of this phenomenon
in the "various diffusion barriers including human resources,
organizational and management practices and more broadly the surrounding
social, economic and institutional environment[11]
.
After
several years of great interest in microelectronics and the information
technology revolution, the center of concern thus shifted to another
wave of equally pervasive but "soft" generic technology. By the
mid-eighties the managerial revolution, centered on the new organizational
practices developed in Japan, had become the focus of a debate
in terms of promises, threats and applicability. Slowly it came
to be understood that the greater success of Japanese firms was
rooted in an organizational model which allowed them to take much
better advantage of modern technologies[12]
.
Since
then there has been a mushrooming of consultancy services in the
new organizational practices, various "gurus" in the field have
appeared and many books and journals are propagating the new principles,
their diverse forms of application and the many specific examples
of success or failure in using them.
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Organization
as the Achilles heel of the traditional technology leader
In
1986 the Massachussetts Institute of Technology set up a special
Commission on Industrial Productivity (MIT/CIP) to address the
causes of the decline in U.S. competitive performance[13]
.
It convened more than fifteen top academics in economics, technology
management and political science who mobilized dozens of expert
researchers to probe into manufacturing companies in eight industries
in three continents. Their results point clearly to the organizational
issues, rather than to hard technology.
The
report groups the causes of the loss of U.S. competitiveness into
six categories:
- Outdated
strategies
- Short
time horizons
- Technological
weaknesses in development and prodution Neglect of human resources
-
Failures of cooperation (within the firm and with other firms
and supporting
institutions
- Government
and industry at cross-purposes
As can
be seen, the great majority are social, organizational and institutional
weaknesses. The first two relate to overall managerial attitudes
to business. The last two refer to the relationship of firms to
other actors in their environment. The fourth is directly related
to human capital. Only the third is truly "technological" in nature.
And yet, when it is spelled out it turns out to be mainly related
to management of technology and attitudes towards it. It includes:
neglect of manufacturability in product design, lack of teamwork
in the product development process, lack of attention to the manufacturing
process itself and poor exploitation of the potential for continuous
improvement in the quality and reliability of products and processes.
When
the MIT Commission analyzed the determining features of competitive
American firms, it also found that at the root of their achievement
were certain common patterns of managerial and organizational practice.
Thus, organizational technology seems to underlie competitiveness
as much as mastery of specific technologies, product innovation
and generic technologies[14]
.
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A
change in common sense and the difficulty of diffusion
What
is happening in the field of management and organization can be
understood as a replacement of the established paradigm for best
practice. It is an upheaval in common sense notions of efficiency.
The principles that are today recognized as leading to competitiveness
are almost all in direct opposition to traditional views. These
are presented in two "pure" models in Figure 4.
THE
NEW VS. THE TRADITIONAL PARADIGM:
A
RADICAL AND DIFFICULT SHIFT IN MANAGERIAL COMMON SENSE
|
|
CONVENTIONAL
COMMON SENSE
|
NEW
EFFICIENCY PRINCIPLES & PRACTICES
|
|
COMMAND
AND
CONTROL
|
Centralized
command
Vertical control
Cascade of supervisory levels
"Management Knows best"
|
Central
goal setting & coordination
Local autonomy/Horizontal self-control
Self-assessing/self-improving units
Participatory decision-making
|
|
STRUCTURE
AND GROWTH
|
Stable
pyramid growing in height and complexity as it expands
|
Flat
flexible network of very agile
units/Remains
flat as it expands
|
|
PARTS
AND LINKS
|
Clear
vertical links/Separate specialized funtional departments
|
Interactive,
cooperative links between functions along each product line
|
|
STYLE
OF OPERATION
|
Optimized
smooth running organizations
Standard routines and procedures
"There is one best way"
Definition of individual tasks
Single function specialization
Single top-down line of command
Single bottom-up information flow
|
Continuous
learning and improvement
Flexible system/Adaptable procedures
"A better way can always be found"
Definition of group tasks
Multi-skilled personnel/Ad hoc teams
Widespread delegation of decision making
Multiple horizontal and vertical flows
|
|
PERSONNEL
AND TRAINING
|
Labor
as variable cost
Market provides trained personnel
People to fit the fixed posts
Discipline as main quality
|
Labor
as human capital
Much in-house training and retraining
Variable posts/Adaptable people Initiative/collaboration/motivation
|
|
EQUIPMENT
AND INVESTMENT
|
Dedicated
equipment
One optimum plant size for each product
Each plant anticipates demand growth
Strive for economies of scale for mass production
|
Adaptable/programmable/flexible
equipment
Many efficient sizes/Optimum relative/
Organic growth closely following demand
Choice or combination of economies of scale, scope or specialization
|
|
PRODUCTION
PROGRAMMING
|
Keep
production rhythm; Use inventory to accomodate variation
in demand
Produce for stock; shed labor in slack
|
Adapt
rhythm to variation in demand
Minimize response time ("Just-in-time")
Use slack for maintenance and training
|
|
PRODUCTIVITY
MEASUREMENT
|
A
specific measure for each department (purchasing,production,marketing,etc.)
Percent tolerance on quality and rejects
|
Total
productivity measured along the chain for each product line
Strive for zero defects and zero rejects
|
|
SUPPLIERS,
CLIENTS AND COMPETITORS
|
Separation
from the outside world:
Foster price competition among suppliers Make standard products
for mass customers Armsength oligopoly with competitors.The
firm as a closed system
|
Strong
interaction with outside world:
Collaborative links with suppliers,with customers and, in
some cases, withcompetitors (Basic R&D for instance)The
firm as an open system
|
As
regards the shape of the firm, the ingrained ideas of centralized
command, pyramidal structures and functional compartments are
being replaced by flat flexible networks with increasing decentralization
of decision-making in structures where top management takes on
a truly strategic and coordinating role. The goal of standardizing
and optimizing operational procedures and specializing people
in clearly defined tasks is being superseded by a trend towards
flexible and adaptable systems based on multi-skilled personnel
and continuous learning and improvement. Similar contrasts exist
for each of the other characteristics.
But
this is not just a collection of new management techniques. Rather
these trends converge into a coherent system, a model or paradigm
of best practice which is proving superior in achieving higher
productivity, quality and overall competitiveness in international
markets. It is thus generating powerful signals which induce imitation.
Even under strong competitive pressures however the diffusion
of the new organizational patterns from one firm to another confronts
great hurdles and obstacles, especially mental blocks and personal
or group resistance. A change in mentalities, attitudes and behavior
is far more demanding than the introduction of modern equipment.
Yet
the people who occupy leadership positions today and must make
the decisions for change are likely to have reached the top by
applying the very principles that are now being questioned. It
is very difficult to accept that what worked in the past has to
be replaced by other practices; that one's competence is threatened
with obsolescence. The MIT-CIP report put it very succinctly in
relation to the U.S.: "it is the very magnitude of past successes
that has prevented adaptation to the new world"[15]
.
Certainly,
the transition implies that entrepreneurs, managers, labor leaders
and government officials must discard a significant part of their
accumulated human capital, of their cherished routines, of their
hard earned experience. Thus transformations do not and cannot
occur overnight. They take decades.
Elsewhere
we have suggested that the delay in implementing change in the
old front runners is one of the elements opening a window of opportunity
for the lagging countries to accelerate development during paradigm
transitions. Another is the availability of generic all-pervasive
technologies that are capable of rejuvenating mature technologies
and revitalizing traditional ones. In so doing, they can reduce
an important part of the gap that had been built on the type of
experience which is made obsolete by the technical and organizational
shift[16]
.
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Reorganization
as an effective option of modernization
Recent
experience in developing countries has shown that much ground
towards competitiveness can be covered with organizational efforts
and modest investment in intangibles. There are many examples
of impressive cost reductions and quality improvements, of successful
rationalization and specialization that have resulted from managerial
reconversion[17]
.
Such cases show that not all modernization processes involve great
expenditures in new equipment.
One
particular study that does quantify the initial trade-off between
hard and intangible investment is the case of a U.S. paper mill
presented in the Harvard Business Review[18]
.
It is worth summarizing it here as an illustration of the type
of effort involved and the sorts of results that can be achieved.
In
1983 the mill was losing a million dollars a month and was the
last of the five suppliers in their part of the market. Equipment
modernization costs were estimated to be $23 million with a timetable
of at least five years to reach break-even. The choice
was filing for bankruptcy or trying the reorganization route.
They did the latter.
The
company decided to turn everyone into a problem solver. "Together,
managers and mill workers learned to take the initiative not just
for identifying problems but also for developing better processes
for fixing problems and improving products... The entire organization
learned how to learn[19]
". They established contact with customers, pinpointed the flaws
that had to be corrected, went to the root causes in their process
and, in the end, not only corrected those problems (going to "zero
defects") but actually developed a new thinner paper grade which
created a profitable niche in the market.
In
less than two years the mill was making profits, by the third
year they had become the number one supplier in their group with
a tenfold rise in prices per share and capable of financing expansion
out of profits.
This
case could be seen as a metaphor for the type of transformation
that developing countries might be wise to attempt in this transition.
With scarce investment capital and without much time to spare
to achieve results, it makes a lot of sense to take the organizational
route to modernization and to concentrate resources on learning.
To
start by investing in new equipment means in most cases the highest
financial cost although it is probably the line of initial least
resistance and minimum effort (See Figure 5).Established practice
both in firms and credit institutions assumes this to be the "normal"
route
[20]
. Yet, it is increasingly recognized that reorganization cannot
be avoided and is in fact required if full benefits are to be
reaped from the introduction of new equipment.
Choosing
to begin by reorganizing has several advantages, one of which
is the trade-off between maximum effort and minimum
cost.
This is obviously important when investment funds are scarce.
But, as the example of the paper mill illustrates, it can be a
better route independently of cost comparisons. Increased innovativeness
allows each step to be financed by the previous, leading therefore
to greater financial autonomy.
Many
individual examples show that a sequence of investment moving
from intangibles to tangible equipment can optimize both short
and long term returns. A process of reconversion that begins with
market analysis and focusing and goes on to investment in human
capital and technological learning, can be followed by a series
of incremental improvements to the existing equipment and process
as well as to the products and, by collaboration with suppliers,
to improve material and technical inputs. This sequence leads
to a full understanding of the potential and limitations of the
machinery in place and to a much greater capacity to select the
new equipment when the moment comes to incorporate it. Often,
as in the case of the paper mill, cash flow from success in the
earlier phases can finance each subsequent one [21]
.
A
point worth making is that this sequence is not only applicable
to the modernization of existing plant but helps to avoid waste
in hard investment when designing new production facilities. In
many instances, the customary practice of estimating market demand
for the medium term and setting up a plant of that future scale
is no longer advisable. Instead of living with idle capacity (and
having funds tied down in it) the lowest possible module is used
at start up and capacity is stretched to follow the increase in
market demand through incremental improvements, additional shifts
or even partial subcontracting. When the next module is finally
added, it incorporates the stretching improvements and takes advantage
of the people trained in the extra shifts. This is of course not
possible in all cases. Bulk production for the standardized portion
of any market is likely to remain dependent on a large enough
scale of production for cost competitiveness. But as soon as more
specialized segments are envisaged, modularity becomes a possibility.
Of course in some cases smaller modules in equipment are simply
not yet available and in certain cases they might never be. Yet,
even in steel, minimum scale has already come down from two million
tons to 300.000 [22]
.
Therefore, the range of options depends heavily on the market
niche being targetted, on the specific product, the particular
technology and even the moment in time.
Nevertheless,
the principle of avoiding idle capital is generally applicable,
sometimes in rather indirect and imaginative ways. For instance,
electric utilities in the U.S. have been able to postpone investment
by purchasing extra power from large customers who have generating
capacity and using it to cover peaks in demand or by financing
energy conservation in the clients' premises[23]
.
Finally
a note of warning. The emphasis placed here on the growing importance
of organizational issues must be situated within the current period
of restructuring and transition. It is not intended to deny the
need for new equipment or R&D efforts. In the medium and long
term the balance between investing in managerial change or in
product and process innovation is biased towards the latter. Once
the new managerial principles become the shared common sense and
point of departure, a greater effort will be required in product
and process technology. Facing these costs, which are likely to
grow as the process of restructuring proceeds, is one of the tasks
that might more effectively be met through international linkages.
Intercountry arrangements established in this transition phase,
moreover, might contemplate from the start this probable evolution.
We
shall return to the theme of market segmentation and international
linkages in Section 5, but we now turn to the issue of human resources
without which neither technical nor organizational change can
be implemented.
|
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| NOTES:
|
| [10] |
INGERSOLL
Eng., (1985), and DEMPSEY,
P.A., (1984)
(back
to text) |
| [11] |
SOETE,
L., in OECD/TEP
op.cit. (Ref.3), Part II
(back
to text) |
| [12] |
In
fact these two waves of change share common features and are
strongly complementary. For a discussion on this see PEREZ,
C., (1991)
(back
to text) |
| [13] |
DERTOUZOS,
M., LESTER, R, AND SOLOW, R., (1989)
(back
to text) |
| [14] |
When
giving due weight to the various factors determining competitiveness,
it must be borne in mind that the U.S. firms being analyzed
are often at the frontier of "hard" technology which is precisely
what makes it paradoxical that they should be losing out in
competition.
(back
to text) |
| [15] |
DERTOUZOS,
M., LESTER, R. and SOLOW, R., op.cit. (Ref. 13)
(back
to text) |
| [16] |
See
PEREZ, C., op. cit. 1989 (Ref.1) and
PEREZ, C. and SOETE, L. in
DOSI, G., et al. (eds.), op.cit. (Ref.1), pp.458-479
(back
to text) |
| [17] |
There
is a set of reports on the results of organizational change
in Venezuelan firms, which are part of a program funded by
the Andean Development Corp. (CAF) for training consultants
in modernization. They show gains in productivity, reduction
of waste and rejects, increases in production, savings in
raw material and energy, etc. from efforts in organizational
change alone. See FIM-Productividad, (1990-91). For a detailed
study of the evolution of a company in the U.K. and its results,
see
KAPLINSKY, R., (1991)
(back
to text) |
| [18] |
SIRKIN,
H. and STALK, G., (1990), pp. 26-33
(back
to text) |
| [19] |
SIRKIN,
H. and STALK, G., op.cit. (Ref.18) p.26
(back
to text) |
| [20] |
For
an example of how this route can yield catastrophic results,
see
MYTELKA, L., (1992), pp.243-264
(back
to text) |
| [21] |
For
a comprehensive textbook discussing this and other aspects
of technical and organizational change, see BESSANT,
J., (1991)
(back
to text) |
| [22] |
SKEZELY,
J. , (1987)
(back
to text) |
| [23] |
See
BUSINESS
WEEK, (1984), pp.60-71, and
GELLER, H.S., (1986)
(back
to text) |
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