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Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-0 November 2003 Manufacturing S trategy THE UNIVERSITY OF NEW SOUTH WALES Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-1 November 2003 Manufacturing Strategy Unit 1 The Nature and Role of Manufacturing Strategy 1-2 Manufacturing Strategy: The Nature and Role of Manufacturing Strategy November 2003 Contents Overview Learning Outcomes What is Strategy? Organisational Goals Characteristics of Strategy Corporate Strategy and the Strategic Business Unit Linking Manufacturing Strategy with Corporate and Business Strategies Conclusion Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-3 November 2003 Overview This unit examines the nature of manufacturing strategy, and its relationship with corporate strategy on the one hand, and with other functional strategies of marketing and finance on the other. The first section commences with a description of the goals of a typical manufacturing organisation in terms of purpose, mission and objectives, and how the overall strategy formulation process is concerned with formulating means of achieving an organisations objectives in the presence of competitive forces. The second section examines the differences between strategic and operations planning in terms of time scale and level of detail. From here we move on to consider the notion of corporate strategy, which considers the corporate mission of the organisation as a whole, the markets in which it will or will not participate, and the nature and role of the separate individual strategic business units of which it is composed. The functional strategies (manufacturing, marketing and financial) of the individual strategic business units, and how these relate to each other and to the overall business strategy. In particular, a blueprint for a new role for manufacturing in the strategy formulation process is developed, and reasons are examined for the subsidiary role often taken by manufacturing in the past Finally we look briefly at how manufacturing strategy and its formulation should be linked by a process of continuous iteration, with corporate and business strategies. Learning Outcomes After studying this unit, you should be able to: • analyse the goals of an organisation in terms of its purpose, mission and objectives • appreciate the key characteristics of strategy and the strategy formulation process. • understand the differences between strategic and operational planning. • appreciate the concepts of corporate strategy, and strategic business units • understand the role of manufacturing strategy and its relationship to corporate strategy, and to marketing and financial strategies. Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-5 November 2003 What is Strategy? Strategy, according to the dictionary, is variously defined as: “the art or skill of careful planning towards a desired end” “the art of devising or employing plans towards a goal” “skillful management of getting the better of an adversary”: “science or art of combining and employing resources in planning and directing major (military) operations” For many years, strategy was used in a military context to denote “grand plans” made in the light of what an adversary might or might not do. In the context of modern business, strategy still has a competitive implication (in relation to an enterprise’s business rivals), but it is also used increasingly to denote broad, overall courses of action, and some form of implied deployment of both emphasis and resources to achieve some comprehensive set of objectives. Note that strategy is defined as being both a science and an art. In this subject we shall inevitably focus on the more systematic (and hence more “scientific”) aspects of strategy development, rather than the “gut feel” aspects associated with strategy development as an art. Organisational Goals Before we look at the concept of strategy in more detail, we must examine the important concept of organisational goals. Organisational goals provide the basic sense of direction and purpose for an organisation and may be usefully divided into a hierarchy of the three slightly more specific concepts of: • purpose • mission • objectives as shown in Fig 1.1 1-6 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 The purpose of an organisation is its primary role as defined by the society in which it operates, and applies to all organisations of that type in society. In the context of private industry, arguments can occur as to the purpose of a profit-making organisation. From an economic rationalist perspective, the ultimate purpose of any profit making organisation is to make a profit (i.e. make money). Thus the ultimate purpose of any privately funded organisation may be regarded as being that of being profitable and making money both now and in the future. The mission of an organisation is the unique aim that sets it apart from others of its type, and may be regarded as the vehicle through which it achieves its purpose. The particular vehicle used by a manufacturing organisation to make money is through the production physical goods. The vehicle used by an airline to make money is to transport people etc. In the case of manufacturing, since the “production of physical goods” is rather too general to be useful, it is normally stated in terms of the specific types of product manufactured and the markets served... If at any stage the particular vehicle used to make that profit ceases to achieve desired results, then the nature of the vehicle, and hence the mission of the organisation, needs to be reviewed. Example: Certain organisations (eg IBM) used to make profits by the manufacture of computers. With the advent of increasing competition, this form of business became less and less profitable. IBM now make most of their profits by selling Information Technology solutions (mostly involving systems and software) rather than manufacturing and selling computers. The wording of mission statements can be important and can indicate significant ways in which the organisation perceives itself. For example a company currently producing glass bottles may consider itself to be operating in the glass bottle industry, its mission being to satisfy customers who require glass bottles. A similar company also currently manufacturing glass bottles may take a broader view of its mission which it might regard as being to satisfy customers who require liquid containers. Whilst not Purpose Mission Objectives Figure 1.1 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-7 November 2003 excluding glass bottles, this mission statement does not exclude the manufacture of other forms of liquid container (eg plastic) and can imply the servicing of a much wider range of markets than the company who deliberately restricts itself to glass bottles. The mission statement represents an answer to the question “what sort of business are we in?” or conversely “what sort of business are we not in?” For example the glass bottle manufacturer might deliberately choose not to broaden its mission statement, so as to focus on those sections of the market that specifically require glass. Implicit in the mission statement will be the particular posture the organisation intends to adopt in relation to its competitors (eg “to achieve the shortest customer delivery time in the industry at the same time as maintaining acceptable levels of cost, quality and product range”.) Objectives are the translation of the mission statement into specific concrete targets against which results can be measured. Specific objectives might represent milestones in fulfilling the organisation’s mission - eg “increase market share by 5% per year over the next 5 years”, or “half product lead times over the next two years” A pertinent question to ask at this point is “who decides the purpose, mission and objectives of an organisation?” In private manufacturing industry, it would normally be accepted without question that the owners of the company (be they an individual, a small group of individuals, or a large number of small shareholders) would have the absolute right to determine the company’s purpose. A more enlightened modern view however is that when purpose is being decided, the views of all the stakeholders should be considered. Stakeholders generally comprise a larger group than merely the owners, and in a large organisation might consist of: • shareholders • employees • customers • suppliers • local community etc This is not to say that strategy should be jointly decided by the stakeholders, but that on the other hand responsible strategy formulation should take into account the interests of the various stakeholders, since alienation of one particular stakeholder group might well have adverse consequences for the company in the longer term Reading 1.1 Stop now and read “The Purpose of the Firm” by Andrew Campbell, Long Range Planning, Vol. 26 No 6 pp140-141, 1993 1-8 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 Exercise 1.1 For your own organisation or one which is familiar to you, indicate the purpose, mission, and a number of specific objectives Characteristics of Strategy Strategy then is the broad program for achieving an organisation’s objectives and so implementing its mission. It creates a uniform direction and consistency in actions, and guides the way in which resources are deployed. Conversely, in cases where the “strategy” of an organisation does not appear to be very clearly formulated, it can also be regarded as the pattern of the organisations response to its environment over time (i.e. an organisation’s strategy, rather than being explicit, is implicitly contained in the way the organisation behaves). Hayes and Wheelright (1984) have identified five key characteristics of the term “strategy” when used in a business oriented sense: 1. Time - strategy is concerned with activities that involve an extended time horizon in terms of both their implementation and their impact. 2. Impact - the eventual impact of pursuing a given strategy will be significant. 3. Concentration of effort - effective strategies normally require concentration of focus on a fairly narrow range of pursuits. 4. Pattern of decisions - strategy implementation requires a consistent pattern of mutually supportive decisions over time 5. Pervasiveness - strategy embraces a wide range of activities from overall resource allocation to daily operations; the need for consistency over time requires that all levels of the organisation act instinctively in a manner that supports the strategy. Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-9 November 2003 Hax and Majluf (1988) have reviewed the definitions of business strategy and have produced a slightly different summary. According to them, strategy: 1. is a coherent, unifying and integrative pattern of decisions; 2. determines and reveals the organisational purpose in terms of long term; objectives, actions, programs and long term allocation priorities; 3. selects the business the organisation is in or is to be in; 4. defines the kind of economic and human organisation the company is or intends to be; 5. attempts to achieve a long term sustainable advantage in each of its businesses by responding properly to the opportunities and threats in the firms environment and the strengths and weaknesses of the organisation; 6. engages in all the hierarchical levels of the firm (corporate, business, functional); 7. defines the nature of the economic and non-economic contributions it intends to make to its shareholders. Note how the critical question of “how do we compete?” is a pervasive theme in this definition. An organisation’s strategy should evolve from the answers to such basic questions as: • What business are we in? If this is defined too broadly the organisation may lack focus; if too narrowly, it may overlook attractive opportunities. • Who are our customers and who should they be? Examination of needs and characteristics of customers may point out the future direction for an organisation to take. • Where are we heading? Is the organisation’s market share increasing or decreasing? Does it need to diversify, or is more focus required? • What particular competitive advantages do we enjoy? What currently existing factors such as unique technology, proximity of suppliers, give the firm a strong advantage over its direct competitors, and how can these advantages be best exploited? • What are our particular strengths and weaknesses? Special capabilities such as a high degree of engineering excellence or a comprehensive distribution network, or weaknesses such as lack of experience in product innovation, can be very significant in determining future strategy. An organisation should embark on a course that makes maximum utilisation of its strengths and minimises its weaknesses. Answers to the above questions help to determine what H. Igor Ansoff has called the “common thread” for the organisations activities. Over-diversified organisations tend to lack this common thread and hence often lack any clear strategy. It has actually been suggested that the most successful organisations are in fact those that have properly identified their “core” 1-10 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 business which they know and in which they can excel, and stick to it in spite of temptations to expand by branching into other areas with which they are less familiar. Reading 1.2 Stop now and read “Why do Companies Overdiversify?” by Andrew Campbell, Long Range Planning, Vol 25, No 5, pp 114-116, 1992 Exercise 1.2 1. Think of an example of a company which has overdiversified to the point where a loss of effectiveness is occurring. What reasons can you think of for the loss of effectiveness? 2. Think of an example of a company that has diversified without any loss of effectiveness. What are the main differences between this and the first company? Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-11 November 2003 Strategic and Operations Planning If strategy provides a set of broad goals stemming from the common thread of an organisation, and the vision for achieving them, strategic planning is concerned with the process of developing specific programs and policies for implementing the strategy. Strategic planning bears a hierarchical relationship to operations planning as shown in Fig 1.2. The strategic plan generally provides the framework within which operations planning, at the more detailed level, will take place. Some of the essential differences in the nature of strategic planning and operational planning are shown in Fig 1.3. Strategic Planning Operations Planning • Long time horizon • Less certainty • Less Structured • More ends-oriented • Poorly defined information requirements • Tends to have irreversible impact • Focuses on the whole • Short time horizon • More certainty • More structured • More means-oriented • Well defined information requirements • Tends to have reversible impact • Focuses on parts Strategic Plan Operations Plan Figure 1.2 Figure 1.3 1-12 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 Due to their longer time horizons, strategic plans are made with more uncertainty than operational plans since making accurate forecasts far into the future is difficult. Strategic plans are also less structured than operational plans for two reasons. Firstly they are more ends-oriented in the sense that goals and objectives must be decided before the means of achieving them (the object of operational plans) can be determined. Secondly, strategic plans tend to have poorly defined information requirements. We can be less certain about the type of information that will be needed to make a strategic choice now that may not have an impact for five years. Operations planning is by contrast more routine, repetitive and requires quite specific information. Strategic plans lead to decisions that are major commitments of present and future resources. As a result, they tend to have irreversible impact. An operational choice, such as how much to order this month from a certain supplier, has far less impact than whether or where to build a new factory. If a mistake is made in the former, a supplemental order can be placed. If a mistake is made in the latter, the firm may be stuck with a costly, inefficient facility. Finally, strategic planning focuses more on the whole organisation and strategic plans made for different functional areas and departments need to be very closely integrated with each other. Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-13 November 2003 Corporate Strategy and the Strategic Business Unit The relationship between Strategic and Operational planning is one form of hierarchical relationship that exists between different types of planning activities in an organisation. A form of hierarchical relationship also exists between different forms of strategy and strategic planning (see Fig 1.4) Deciding on the common thread underlying an organisation’s activities (i.e. the particular industry in which it will operate, the markets it will serve etc) it would not be uncommon to find the organisation to be composed of more than one “business”. In the paint industry for example, a single company could be involved in five businesses - eg: 1. decorative or architectural paints 2. industrial coatings 3. automotive paints 4. refinish paints 5. marine coatings Although the common thread, paint manufacture, clearly exists, each business has different market requirements in for example, customer service, and each will have a visible and obvious set of competitors. Each business will be operating in different product/market environments and as such, different bases for competitive advantage and different strategies for achieving it are likely to be appropriate. The term strategic business unit has been coined to describe a separate business entity with its own particular strategic focus. The most logical top- level division of the organisation is therefore into such strategic business units. Obviously, only larger companies will divide into separate strategic business units in this way. Many smaller companies will comprise only single business units and so this top level division will be absent. Corporate strategy is concerned with defining the overall corporate mission of the organisation as a whole, the product/markets in which it will or will not participate, the nature and scope of each Strategic Business Unit, the way in which the individual units will be funded, how resources will be allocated between them, what types of performance measure will be used, how return to shareholders will be established etc. Each strategic business unit will have its own business strategy and strategic plan that is appropriate for the particular product/market situation in which it is operating. This will be concerned with the particular way in which the 1-14 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 units has decided to compete, the cash flow and expected profitability of the unit and the ways in which this will relate to the corporate plan. The strategy for each unit may be broken down into three functional strategies: • a marketing strategy • a financial strategy • a manufacturing strategy The marketing strategy is generally concerned with the range of products that will be made, where and to who they will be sold, and at what price. The typical questions to be answered in formulating a marketing strategy are: • who are our customers? • where are our customers? • what do our customers want (eg price, value, quality, availability, service?) • how much will they buy at what price? • do we wish to be a market leader? • how is it best for us to sell? • what sort of channels do we need for distributing the product? • do we need and can we supply supporting services? • what is the best pricing strategy and policy for our operation? The financial strategy is concerned with establishing targets of profitability, productivity, capital investment, and the allocation of funds between different activities. Typical questions to be asked in formulating a financial strategy are: • what level of profits and profitability should be targeted over the next few years • what type of payback period will be required on new capital investments If we assume that the strategic business unit is divided into the different functional areas of finance, manufacturing and marketing, Given a good marketing and financial strategy it is necessary that the manufactured by the company be produced in the right quantity, at the right time, to an appropriate standard of quality and at a cost which ensures the company will remain profitable. In other words, the product must be manufactured competitively. The manufacturing strategy is concerned with developing a broad framework for the acquisition and maintenance of the appropriate resources, technology, skills, management systems, quality assurance systems, maintenance systems etc to do this. Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-15 November 2003 Skinner (1983) has defined manufacturing strategy as: “...a long-term plan for developing consistent operations policies and structures and providing focused facilities to achieve limited but absolutely key corporate strategic objectives. This is a matter of designing the parts to do the job for the whole of the corporation. It's also designing the part so that it is a focused part and doesn't try to do everything. Manufacturing strategy is addressed to key structural decisions. By structural, I mean the decisions that lock your operation in for years--things that are hard to change, the number of plants, the size of the plants, the location of plants, the major systems for control, organization, and human resource management, the selection of the equipment and process technology. Those are the long-term structural decisions. Heaven help you in your operation if you've got the wrong plant or the wrong equipment at the wrong place with a whole pipeline of people who have been selected and trained and supervised and managed wrong. We are talking about trying to look ahead to the strategic objectives and plans.” Manufacturing strategy should basically: • provide manufacturing processes that give the business a distinct advantage in the marketplace • provide coordinated support for the essential ways in which products win orders in the market place at a better level than competitors By achieving the first of these two objectives, manufacturing will be able to provide a marketing edge through distinct, unique technology developments in its process and manufacturing operations which competitors are unable to match. By achieving the second, manufacturing develops a set of policies in both its process choice and infrastructure design (for example controls, procedures, systems and structures) which are consistent with the existing ways in which products can win orders, whilst being able to reflect future developments in line with changing business needs. In the past, manufacturing decisions have traditionally been subservient to financial and marketing decisions in that the former are made by the relevant directors without any reference to the capabilities of the manufacturing function to deliver the necessary outcomes required by such decisions. Marketing decisions and plans were merely handed down to manufacturing who were supposed to simply accept them without question, and do the best they could. The manufacturing function frequently did not have any representative on the board of directors who would be primarily responsible for setting strategic direction. This type of relationship between manufacturing and other functional strategies is shown in Fig 1.4. 1-16 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 A more modern view of the relationship between the functional and corporate strategies is shown in Fig 1.5. Here, manufacturing strategy has been raised to equal partnership with financial and marketing strategies. Figure 1.4 Figure 1.5 Relationship between Functional Strategies (modern) Business Strategy Marketing Strategy Financial Strategy Manufacturing Strategy product technology process technology process positioning capacity strategies degree of focus experience curve issues human resource issues interaction with suppliers/customers (supply chain issues) Manufacturing Plans Relationship between Corporate and Functional Strategies (traditional) Corporate Strategy Marketing Strategy Financial Strategy What business or businesses are we in? Degree of diversification Mergers/takeovers Cash allocation between businesses Relation with shareholders Relation with society Debt/equity financing Capital budgeting Return on investment target s Taxation Liquidity/Cash flow issue s Financial performance goal s In what markets to compete? With what products? Competitive advantage exploited Advertising and promotion Product image Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-17 November 2003 Note how this relationship is not strictly speaking a hierarchical one. The major functional strategies in one sense are part of but also serve to define the business strategy. Likewise marketing, finance and manufacturing strategies are equally important in defining the business strategy with no single functional strategy taking precedence over the others. This is consistent with the modern notion that properly formulated and implemented manufacturing strategies provide a powerful platform to launch new competitive thrusts. Whereas an effective marketing strategy can ensure that a company can get and stay close to the customer and can identify market niches associated with particular forms of competitive advantage, such that customers will want to buy from your company and no other, the manufacturing function is the engine that drives and supplies the power that the marketing function can exert in the marketplace. Thus any strategic corporate or marketing decisions that are made should be in full conjunction with a complementary set of strategic decisions about the manufacturing infrastructure that will need to be available to implement these decisions, and will allow manufacturing policies to be aligned “hand- in-glove” with marketing and financial policies. This contrasts strongly with the older style view of manufacturing having only a reactive role in business strategy. Reading 1.3 Stop now and read “Setting the Strategy” Tangram Technology, 2001 Exercise 1.3 Make notes in the space below on the points in this article that you see as being relevant to your own organisation 1-18 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 The reasons for manufacturing’s traditionally reactive role may be examined by looking at how manufacturing organisations have evolved in recent history. Up to the mid 1960’s manufacturing companies could generally sell all they produced, and this created a dominance for the manufacturing function in many organisations. From the mid-1960’s to the mid 1970’s, selling into existing and new markets became more difficult, and marketing became the pre-eminent function. From the 1970’s onwards, recessions, energy crises, and shortage of key resources opened the door to the influence of the finance function, and this has increased in recent years with corporate restructuring, mergers, the creation of “paper” organisations, and the need to maintain the organisation’s listed price in the stockmarket as a defence against corporate takeovers. The latter has also lead to renewed emphases on cost minimisation (generally pertaining to manufacturing costs) and asset liquidation and a rather short term view being taken of capital investment decisions, which has not encouraged the renewal of ageing plant and equipment or investment in new technology. All of this has lead to a progressive decline in the influence of the manufacturing on corporate or business strategy which has been further exacerbated by typical internal organisational factors the more typical of which are listed below: • production managers view of themselves; production managers tend to define their role as that of merely reacting as well as possible to what is asked of the manufacturing system, rather than as making a contribution to corporate decisions. • company’s view of the production manager’s role; many production managers started their careers on the shop floor, or as technical or engineering specialists. Promotion often occurs with scant regard to the change in emphasis required if a more corporate perspective is to be taken of manufacturing’s role. • production managers are too late in the corporate debate; often production managers are not involved in corporate policy decisions until these decisions have started to take shape, hence they have little opportunity to contribute to decisions on strategy alternatives. • the “can’t say no” syndrome; production managers tend to accept the current or future demands placed on them and attempts to resolve them, rather than providing realistic feedback up the corporate chain as to what is and is not possible. • functional goals and measures; whereas finance and marketing divisions tend to be measured in terms of overall effectiveness such as total profits, or total sales achieved (a business perspective) production divisions are usually measured in terms of efficiencies (an operational perspective). A focus on efficiency rather than effectiveness can lead to decisions which are sub-optimal from the point of view of the organisation as a whole. Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-19 November 2003 • top management’s view of strategy; top level executives in a business tend to look outwards and centre their attention on the external environment in which the business operates; as such the outward looking perspectives associated with marketing and finance will occupy most of their attention. Manufacturing on the other hand is concerned with the inward dimensions of the business with which top executives are less likely to want to be associated. 1-20 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 Linking Manufacturing Strategy with Corporate and Business Strategies We have implied a degree of equality between the three functional strategies and how they collectively define the business strategy. This has an impact on the process of strategy formulation, which for a manufacturing organisation classically consists of the following steps: 1. Define corporate/business objectives 2. Determine marketing and financial strategies to meet these objectives 3. Assess how different products win orders against competitors 4. Establish the most appropriate mode to manufacture these products - process choice. 5. Provide the manufacturing infrastructure required to support production. The problem in the past tends to have been that most corporate planners tend to treat the first three steps as iterative with “feedback loops” and the next two as linear and deterministic (i.e. process choice and manufacturing infrastructure somehow follow from the first three) in reality the manufacturing infrastructure that currently exists, and current process combined with those that are realistically implementable in the time frame given existing skills and expertise, should also have a strong input to the first three steps. This implies the whole process should be an iterative one. Exercise 1.4 Try to think of some examples from your own organisation or from organisations known to you, of some negative effects of failing to regard strategy formulation as an iterative process Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy 1-21 November 2003 Conclusion We have seen in this unit how a successful manufacturing company requires a long term and coherent strategy for survival, and that this strategy should comprise a set of integrated functional strategies of which the manufacturing strategy plays an equally important role to that of the financial and marketing strategies. We have also seen how the development of a strategy is an iterative process between the three functional strategies, the strategy of the business unit, and the corporate strategy. In the succeeding units we look at various components of the manufacturing strategy to see in more detail how “integration through iteration” can occur. 1-22 Manufacturing Strategy: Unit 1 - The Nature and Role of Manufacturing Strategy November 2003 References Hax A.C and N.S. Majluf “The concepts of strategy and the strategy formation process”, Interfaces, Vol 18, pp99-109, May-June 1988 Hayes R.H. and S.C. Wheelright, “Restoring our Competitive Edge: Competing through Manufacturing” NY, John Wiley, 1984
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