From the Diffusion of Lean Production to the Hybridization Perspective : Studies on the Transfer of the Japanese Production System to the U.S.
著者 KUMON Hiroshi
出版者 Institute of Comparative Economic Studies, Hosei University
journal or
publication title
Journal of International Economic Studies
volume 14
page range 27‑40
year 2000‑03
URL http://doi.org/10.15002/00002168
FromtheDifhsionofLeanProduction
totheHybridizationPerspective:
StudiesontheTrans化r
oftheJapaneseProductionSystemtotheU.S、
Hiro二MKumon
Pm/tsso7utHOs`iU>ziue酒j醜FlUc"ノワq/Sociα/Sci`〃c圏S
Abstract
Formorethantwodecadesnow,groupsofAmericanresearchershavestudiedtheJapa- neseproductio、system,inresponsetoeconomicevents・TheHr5teventwasanincreaseof importsfiPomJapan・Thesecondwasthetrans化roftheJapanesesystemtotheU.S、Ameri- canresearchersdevelopedtheterm“Ieanproduction”basedontheirfYeldresearchinautomo‐
tiveplantsthroughoutthewo「1..TheywentonHeldresearchtotransplantsofJapanesenrms andemulatorsamongindigenousfIrms・Thethemeoftheirstudywasthetransferabilityof theJapanesesystemtotheU・STheyreachedtheperspectiveofhybridizationthroughneld studiesontransplantsandemulators・Thispaperaimstotracetheevolutionaryprocessof studiesontheJapaneseproductionsystemanditstransfbrtotheU・SThesestudiesdefined specificfeaturesoftheproductionsystemandraisedproductiveissuesregardingorganiza-
tionaltransfeTsacrossborders、
1.Introduction
ThispaperaimstoidentifyresearchstudiesonthetransfbroftheJapanesepro- ductionsystemintotheUSA,andtoclarifypointsatissue・Inthel980s,theJapanese productionsystemwasseenasanalternativemodeltotraditionalmassproduction・
Itwasevaluatedasamodelfbrindustrialsurvivalandadoptedinvariousmanufac- turingsectorsaswellasintheautomobileindustry・Researchersgavetheterm“lean production,,tothesystemthatenablestheeliminationofwasteandtheproductionof highqualityproducts・Asleanproductionspread,researchersdiscoveredthatthe systemhadbeenadoptedinseveralpattemsTheJMNESG(JapaneseMultinational EnterpriseStudyGroup)calledthese“hybrid”factories(Abo,1994)andwestern researchersalsoacceptedtheideaintotheiranalysis(BoyeretaL,1998,Likeretal,
1999).Theyaccumulatedempiricalstudiesbasedontheideaandevenraisedtheo‐
reticalperspectives・AstheJapanesesystemspreadmtotheUSAwithvariousfbrms ofadoption,studiesonleanproductionevolvedintothehybridizationpe応pective,
whichincludesrichempiricalresearchesaswellastheoreticalcontributions・
Firstly,someexplanationmustbegivenofAbernathy,spioneeringstudies、I、
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F「omlheDimnSiono『LeanProductiontothcHybridizationPe応peclive:
thel970s,AmericanreseamhersbegantogaininterestintheJapaneseproduction
system,seeingitasanaltemativetomassproduction,whichhadbeendefeatedin internationalcompetition・Abemathystudiedthelimitationsofthemassproduction
systemfromtheviewpointofdeclininginnovatio、.Hefbcusedhisattentionon
Japan,wheretheHexibleproductionsystemhadbeendeveloped,andemphasized industrialrevivalnotinmacroeconomicpolicybutinthesoftwareofthemicroor‐
ganization,namelytheflexibleproductionsystem,Secondly,Iwillexplainthestud- iesonleanproductionanditstheorybyWomacketaLThirdly,Iwillexplainthe hybridizationperspectiveonthetransflerofleanproductiontotheUnitedStates・The transferofleanproductionresultedinakindofmixingwithAmericanmethods・
Researchersdiscoveredvarioustypesofhybridpatterns,andalsomadeproductive
theoreticalstudies.
2.TurningtotheJapaneseProductionSystem
Someproductionmodelswerepresentedasalternativestothetraditionalmass
productioninthel970sandearlyl980s,whenlimitationstotheviabilityofthe traditionalsystemwereappearing,ProminentpropositionsincludedtheJapanese modelbyAbernathy,andtheltalianmodelbyPioreandSabel(Abernathyeta1., 1984,PioreandSabel,1984).Thelatterpresentedamodelofflexiblespecialization,
basedonthenetworkofflexiblesmallHrmslocatedincentralandnorthwesternItaly、
Theyclaimedthatalthoughcraftproductionandmassproductionhadcoexistedin
thel9thcentury,massproductionhadlimitedthegrowthofcraftsystems.They calledthisthe“firstindustrialdivide.”Andnow,theywrote,wearelivingthrough asecondindustrialdividewhichwillleadbacktothecraftmethodofproduction,
requiringanextensionofexistingregulatoryinstitutiona
Abernathyanalyzedthestagnationoftechnologicalinnovationintheautomo‐
bileindustrybylookingatproductionsystems,andproposedamethodofindustrial
revivalthroughtransfbrmationofthetraditionalsystemintoaHexiblemanufacturing
system、Hefbrmulatedamodelfbranalyzingtheevolutionaryprocessofinnovationbothinproducttechnologyand、anufncturingprocesstechnology・Basedonthis
model,hepreciselydefmedthestagnationofinnovationintheAmericanautomobileindustry,andcalledfbrittobechangedintotheJapaneseHexiblesystem、Hisgreat workwasP'D`"αjvhtyDi化mmafRoqd6bckroI""owmO〃j〃rheAmomobjノemdzJsrry (Baltimore&London:TheJohnsHopkinsUniversityPress,1978).HeclarifIed adverseinteractionsbetweeninnovationandproductivity,basedonanempirical
studyoftheFordMotorCompany・Heinvestigatedtheeight-decade-longhistoryof productandprocesstechnologyatFord,sengineplantandassemblyplant・Basedon adetailedanalysisoftechnologicaldevelopmentatthetwoproductiveunits,heclaimedthatinnovationhadstagnatedlnperiodswheninnovationwassta2mant,
productivityincreased,andwheninnovationwasconstant,productivitywassluggish
Astheproductandmanufncturingprocessesdeveloped,costdecreased,andproduct designsbecamemorestandardized・Atthesametime,manufacturingprocessesofL fbredhigherlevelsofproductivity,andbecamedependentonspecializedequipment・Changeofequipmentlaggedbehindmodelchangesandblockedthesmoothnessof productdevelopment・InnovationbecameincrementaLProductivityincreasescon-
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tinueduntiltheindustryreachedstagnation.“Statedgenerally,toachievegainsin
productivity,theremustbeattendantlossesininnovativecapability,,(Abemathy,
1978:4).Althoughhepresentedalogicfbrstagnationininnovation,heleftan openingfbrescapmgtheviciouscircle、Heproposedthisanswerinhisnextbook,in thefbrmofthelogicofde-maturityoftheindustry.(1)
AbernathyetaLraisedtheproblemofindustrialrevival,andfbundtheJapanese
productionsystemtobeanalternativemodeltomassproduction(AbernathyetaL,
1984).HeshedlightontheshopHoorsystemwhereworkers,ideasandskillswere integratedintothemanagementorganization,inawaycompletelydifferentfrom Americanplants,basingthisideaonfieldresearchatJapaneseautomotiveplants、
De-maturityistheconditionwhereinnovationrequiresachangeintraditionalpro‐
ductionsystemwhichiscomposedofskills,systemsandresources・Thelogicof de-maturityfbllowsfromthisTheresilienceofanindustrytakesplaceinfburstages,
consideringthattechnologicalchangehasaninHuenceuponbothproductsandmar‐
ketsThefIrststageisthe,ArchitecturalPhase,,inwhichvariousproductconcepts aredevelopedfbllowingappropriateproductionsystemsaswellassuitablemarkets・
Thenexttwostagesconsistofincrementalchanges,withnoradicalchangesofprod‐
ucts,productionsystemsormarkets,andnewproductdevelopmentfbrnichemarkets・
The‘`ArchitecturalPhase,,setsthemaincourseoftheindustry,wherethebasic designoftheproductisset,anditcreatesconnectionswithmarkets・Itisthenfbl‐
lowedbythe“RegularPhase,,,whereincrementaltechnologicalchangetakesplace、
Thedominantdesigncontrolsthedevelopmentpathoftheindustry、Thisstageis characterizedbythestandardizationofmanufacturingprocessesandstrengthened productionsystems,Thethirdstageiscalledthe‘`NicheCreationPhase.,,Some typesofnewproductsareofYbredduringthisstage,withchangmgrelationshipsbe‐
tweenproductsandmarkets・Thesetwostagesdonotincluderadicalchangesof dominantdesignsormanufacturingsystems,andtherefbrecompetitivenessdoesnot continuefbrlongThefburth“RevolutionaryPhase,,ischaracterizedbyradical changesinproductdesignandinthecompetitiveconditionsoftheindustry,threaten- ingexistingproductio、Systems、Thede-maturityofindustrytakesplaceintheproc- essoftransfbrmationfiPomthe``RegularPhase,,,wheretheindustryisinamatured condition,tothe“RevolutionaryPhase,,,whoseessentialfeatureistheapplicationof newtechnologytoexistingmarkets・ThusAbernathyconnectedaconceptofinnova‐
tionandproductcyclewiththefbundationoftheproductionsystem,basedonin‐
depthanalysis・
HeusesthismodeltoexplainthehistoricaldevelopmentoftheAmericanauto- mobileindustry,bypresentinginfbrmationaboutinnovationindrivetrains・Thefirst cyclebeganatthebeginningofthe20thcentury,andthesecondinthel930s/1940s・
Varioustypesofcarscoexistedduringthearchitecturalphaseintheearly20thcen- tury・Thencametheregularphase,inwhichtheModelTwasdevelopedbyHenry Ford,andwherebothproductstandardizationandprocessinnovationintheflowof lineproductiondeveloped・Therevolutionaryphaseappearedwiththeintroduction oftheclosedsteelbodyinthemid-1920s・Thenewbodyincludedvariousimprove- mentsinsuspensionsystems,enginedesign,etc・Thedominantdesignofthefbllow‐
ing30yearswassetbythedevelopmentofthe“rolIinglivingrooms,,inthel930sand automatictransmissioninthel940s・Changesoccurredfromthelatel930stothelate
l950s,mainlyinvolvingincrementalreHnementsandthecreationofnichemarkets.
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FromtheDiHnsionofLcanProductiomtotheHybridizationPerspective:
Americanautomakersbegantopayattentiontocompactcars,duetotheincreaseof importsfromEuropeandJapan・Thentheindustrywentthroughanewroundof innovationinthel970s,becauseoftheoilshock,Itwasnecessarytomakechanges incompanyorganizationtogiveaboosttotheprocessofde-maturity・Neworgani- zationsrequiredmanagerstolearnnewrelationsamongtechnology,marketand productionsystem、HereAbemathyfbcusedhisattentiononJapaneseautomobile makersasleamingorganizationswhichwerCabletoconcentratetheiremployees,
energyintocompanyactivities(Abemathy,1984:107-118).Incidentally,theMITresearchgroup,whichdevelopedtheconceptofleanpro- ductioninl990,publishedabookofcollaborativeworkinl984(A1tshuleretaL,
1984).Althoughthebooklookedatvariousaspectsofindustry,anddidnothavea centralunifyingtheme,ittookasenouspositiontowaldtheJapanesechallenge・As aresulttheresearchersreachedanaccurateunderstanding,whichleadthemtofbcus ontheJapaneseproductionsystemmtheirnextresearchprOject、Theyarguedthat therewerethreephasesoftransfbrmationsmtheautomotivehistory・ThefHrsttrans‐
fbrmationwasthebreakthroughbyAmericanproducers,aroundl910,fiPomcustom buildingtomassproductionThesecondoccurredinEuropeinthel950s,when Europeanproducerscombinedmassproductionwithanemphasisonproductdiffbr- entiation、ThethirdbeganinJapaninthelatel960s,whenJapaneseautoproducers begantomakedramaticbreakthroughsinproductionorganization・Thecreative breakthroughinproductionsystemsandproductspromotedanexplosionofdemand inthedomesticmarket,andresultedinexportgrowthTheyhypothesizedthatthis wouldbefbllowedbyoneofthreescenarios,eachleadmgtoanewequilibrium・The firstwouldbetheconcentrationofautomobileproductiontoJapanhomtheUSA andpartsofEurope、Thesecondwouldberapidleammgandcostreductionsby
Westernproducer5,andaclosingofthecompetitivegapwithJapan・Thethirdwould befbrgovernmentstobacknationalproducerswithsubsidiesortraderestramts・Thesecondpathwasdesirable,butproducersandlaborunionsaswellasgovernments
facedthechallengeofintroducingnewmanufncturingtechnology(A1tshuleretaL,1984247-252).(2)
3.6`TheTriumphoftheLeanProductionSystem,,
WomacketaL,organizedthelntemationalMotorVehicleProgram(IMVP)at MITinl985,andperfbrmedresearchontheworld,sautomobileplants・JohnF・
Krafbik,amemberoftheprogram,publishedthearticle,“TriumphoftheLean ProductionSystem,,,inwhichheproposedthename“leanproduction,,(Krafbik,
1988).HewasafbrmermanufacturigengineeratNUMMI,aGM-Toyotajomt
venturemCalifbrnia・HecomparedtheToyotaproductionsystemwithFordism,termingthefbrmer“leanproduction,,andthelatter``bufTeredproduction.,,Fordism
hadmanybuffers:highinventorylevels,manyutilityworkersinpreparationfbrhigh
absenteeism,hugerepairareastocompensatefbrpoorassemblylinequality・Ontheotherhand,Toyota,sproductionsystemwasaleanoperationwithoutwaste・Givmg
productivity,qualityandHexibilityastheprimaryindicatorsofplantperfbrmance,hepresentedtheadvantagesofleanproductionovertraditionalmassproductionplants・
Inl990,WomacketaLpublishedZ1ノieMtJcAj"er/iatChα"gEdjAeリリノbrki,which
30
madeagreatcontributiontotheacademicfieldbyshowingtheproductivityand qualityoftheworld,sautomobileplants,basedonfieldresearch・Theydemonstrated thecompetitiveadvantageoftheleanproductionovermassproduction,andclarifHed itsuniversalcharacterintermsoflocation、Alsofromthehistoricalpointofview,
theyproposedthatleanproductionbespreadthroughouttheworld,presentingitas astageintheevolutionaryprocessoftheproductionsystem;namely,けomcraft productiontomassproduction,andthenleanproduction・
Letuslookattheperfbrmanceofleanproduction,asthisisaveryimportant issue、Firstly,letustaketheexampleofal986comparisonbetweenatraditional massproductionplantandaleanproductionplant・Acomparisonbetweentwo plants,GM,sFraminghamandToyota,sTakaoka,fbundthatTakaokastoodat almosttwicethelevelofFraminghaminproductivity,andthreetimesinquality (WomacketaL,1990:81).Grossassemblyhourspercarwerel8,OatTakaokaand 407atFramingham・Theadjustedassemblyhourspercarwerel6atTakaokaand 31atFramingham・Therewere45assemblydefbctsperlOOcarsatTakaoka,versus l30atFraminghamSecondly,acompansonwascarriedoutml989ofassembly plantsinJapan,America,andEurope・Theproductivity(hourspervehicle)wasl68 atJapaneseplantsinJapan,21.2atJapaneseplantsinNorthAmerica,25.1atAmeri- canplantsinNorthAmeriCaand36.2atallplantsinEuropeThequality(defbcts perlOOvehicles)was600atJapaneseplantsinJapan,65.0atJapaneseplantsin NorthAmerica,82.3atAmericanplantsinNorthAmericaand97.Oatallplantsin Europe・Lookingattheregionaldifferencesinperfbrmance,wefindthatthehighest wasattheJapaneseplantsinJapan,fbllowedbytheJapaneseplantsinNorthAmer- ica,andthenAmericanplantsinNorthAmerica、ThelowestwasattheEuropean plants・AlthoughitwassurprisingthattheJapaneseplantsinNorthAmericaper- fbrmedsimilarlytoAmericanplantsinNorthAmerica,theEuropeanplants,which werethelowestamongthedevelopedregions,wereshowntobestillusingmass production・Intermsofplantcharacteristics,thesizeoftherepairarea(as%of assemblyspace),whichisagoodindicatorofqualitycontrolontheshopfloor,was 4.1atJapaneseplantsinJapan,and4.9atJapaneseplantsinNorthAmerica・The Japaneseplantsmthetworegionswereverysimilar・AmericanplantsinNorth Americahadafigureofl2.9,andEuropeanplantsl44・Thosenumbersindicated diffbrencesinqualityassurancesystems・WhiletheJapaneseplantsusedasystemof securingqualityinthemanufacturingprocesses,themassproductionplantsadopted astrategyofrepairingandsecuringqualityatthefinalstageofthemanufacturing
process、
Thebookusedfieldresearchtodemonstratethecompetitiveadvantageoflean productionovermassproductionItalsoshowedtheuniversalcharacterofthelean productionsystemintermsoflocation・SinceJapaneseplantsinJapanandNorth Americaachievedquitesimilarperfbrmances,andAmericanplantsinNorthAmer‐
icaalsocameclose,itbecameclearthatleanproductionwasapplicableinbothre‐
gions、Plantperfbrmanceisnotdeterminedbyanassemblyplant,slocation、These theoristsmentionedthreeobstaclestothediffUsionofleanproductiomOnewasthe resistanceofwesternmassproducers;thesecondoutdatedthinkingabouttheworld economy,fbllowingtheproductlifecycleperspective;andthethirdtheinwardfbcus ofJapaneseleanproducel君,andtheirreluctancetocarryoutproductionoverseas、
WomackandJonesprovidedatheoryofleanthinking(Womack&Jones,
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FromtheDifTUsionofLeanProductiontotheHybridizationPerspectWe:
1996).Althoughtheirintentwastoinstructreadersontheadoptionofleanproduc‐
tionatexistingmassproductionCompanies,Iaminterestedintheprinciplesoflean productionsystemswhichtheyproposed,TheywrotethatHenryFordsimplydiscov- e正dthespecialcaseofHowproduction,andthatTaiichiOhnodevelopedthegeneral casebyintroducmgsmall-1otproductionandquicktoolchangeovers・Ohnodevel‐
opedcontinuousflowproduction,abandoningbatchproductionandqueues・
WomackandJonesmadeadistinctionbetweenprinciplesandtechniques,andpro‐
posedfiveprinciplesfbrleanthinking・ThefirstwastospecifyvaluesfbrspeciHc productsfromthecustomer,spointofview・Thevalueembodiedinproductisonly meaningfillwhenitmeetsthecustomer,sneedsataspecificpriceandaspecifictime,
Thesecondwastoidentifyavaluestream,whichisthesetofallactionsneededto bringaspecificproductthroughthethreebusinessmanagementtasks:designand engineeringoftheproduct,infbrmationmanagementofthetaskoforder-takingand delivery,andproduction,ataskofphysicaltransfbrmationByidentifyingthevalue streamfbreachproduct,onecandivideactivitiesintothreetypes:thosewhichcreate value,thosewhichcreatenovaluebutarecurrentlyunavoidable,andthosewhich createnovalueandareimmediatelyavoidable、Thethirdistoputthevalue-creating stepsintoanow,Theirclaimwasthatoneneededtonotuseintuitivethinkingwith regardtoproduction,groupactivitieswithindepartmentsorfimctions,andtowolk towardperfbrmingactivitiesinbatches・Thepurposeistomakeflowsofvalue‐
creatingactivitiesfbrspecifIcproductbyredefiningtheworkoffimctions,depart‐
mentsandfIrms、Thefburthwastoallowthecustomertopulltheproduct、Lean productionmakesexactlywhatthecustomerwantsjustwhenthecustomerwantsit・
Itmeansonenolongerusessalesfbrecasts,insteadmakingwhatisactuaUyneeded、
Finally,perfectionarrives・Itrelatestocontinuousimprovement・Thefburprinciples interactwitheachother・Puttingvalueintoaflowexposeshiddenwastesinthevalue
stream・Implementingpullsystemrevealsimpedimentstoflow,Theelimmationofwastesometimesrequirenewprocesstechnologiesandnewproductconcepts、By definmgtheprinciples,WomackandJonespresentednewconceptsfbrleanenter‐
prisesimplementingleanprinciples(Womack&Jones,1996:15-98l
LikerexemplifHedtheapplicabilityofleanproductionnotonlytotheautomobile industrybutalsotootherindustries,presentingamplecasestudies、Iamveryinter-
estedinthestoryofFordMotors,whichimplementedleanproductionunderthe
nameoftheFordProductionSystem(Liker,1998).4.TheHybridizationPerspective
LeanproductionspreadtofbreigncountriesbywayofJapanesemultinationals,
indigenousfirms,adoptionofthesystem,andtheactivitiesofconsultants、Various studieshavefbcusedontheinternationaltransfbrofthesystem・Oneissueisthe transfbrabilityofthesystemitselfiwhatpartsal℃transfbrred,andhowThisissue relatestotheconvergenceordivergenceoftheproductionsystem・Anotherissueis thetransfbrmationoftraditionalworkorganizationandlaborrelationswiththe
introductionofleanproduction・Althoughnoobjectionsorcritiqueshaveemerged regardingtheadoptionoftechniquessuchasJITandTQC,therehavebeensharp
difYbrenceonpointsofviewregardingbothworkorganizationandlaborrelations、1t32
seemsthatthereisasubtledifYbrenceonthosepointsbetweenAmericanandEuro- peanresearchers・Americanreseamherstendtoseethetransferabilityofthesystem
inpositivetenns,andtopointtovariousfbrmsofadoptionatdifTerentregionsand
Hrms・Inotherwards,theyseediversitywithinaconvergenceintoleanproduction(Kochanetal,1997).Ontheotherhand,Europeanresearcherstendtofbcusonthe
selectivityofintroduction,orhybridization,basedontrajectoriesofthefirm(Elgar
&Smith,1995,Boyeretal,1998).EvenintheJapanizationdebate,thetermhasbeen
usedasametaphor(oliver&Wilkinson,1992).Inaddition,therehavebeendiffbr‐
encesonthesecondpoint,namelyworkorganizationandlaborrelations・Therehave beenbothpositiveandnegativeevaluationsmtheU・SPositiveevaluationsofthe JapanesesystemintheU.S・havefbcusedonthedifferencewithtraditional Taylorism(Kenney&Florida,1993,Adler,1993a,b,MacDufYie’1992,1995,Pil&
MacDuffie,l997lOntheotherhand,manyresearchersandparticipantsinthelabor movementhavecriticizedthesystem,andlooktothepossibilityofclearclasscon- frontation(Parker&Slaughter,1988,Fucini&Fucini,1990,Babson,1995,Graham,
1995,Besser,1996,RinehartetaL,1997).InEurope,therehavebeenvoluminous reseamhesconsistingofcritiquesorskepticalviewsoftheJapanesesystem・
AlthoughtheJapanesesystemisrecognizedashavingadvantagesintermsof productivityandqualityofproductscomparedtomassproduction,itstransferinto developedcountrieshasmetwithobstacles・Itrequiresatransfbrmationoftheexist- ingworkorganizationandlaborrelations・Generallyspeaking,innovationiswel- comedintheU.S、,thoughitisnoteasytochangeworkorganizationandlabor relations・Also,AmericanmanufncturingfIrmshavetendedtochooseeithervertical integrationorpuremarkettransactionsfbrtheprocurementsofpartsandmaterials、
ItseemsthatithasbeendifHculttochangesuchintegratedsystemsintolong-telm transactionsbetweenassemblersandpartsmakers、Infact,accordingtoastudyon theadoptionofthesystembythebigthreeautomakersinthel990s,theyhavecaught uptoJapanesemakersintermsofreductionsinleadtimeofproductdevelopmentand implementeddesign-inbypartsmakers(Dyer,1996),theyhavenotbeenableto buildreliablerelationshipswithpartsmakers(Helper&Sako,1995).Alsothebig threehavelaggedbehindintheareaoftransfbrmationofworkorganizationatexist‐
ingplants(MacDufTie&Pil,1997).
Kenney&F1oridalabeledtheJapanesesystem“Innovation-mediatedProduc‐
tion,,(Kenney&Florida,1993).TheybegantheirresearchontheHondaofAmer‐
icaManufncturingplantatMarysVille,Ohio,andextendedittotheoverallquestion ofthedifYilsionoftheJapaneseproductionsystemintheU.S・Incontrasttothemass productionsystem,whichmakesadistinctionbetweenmentalandmanualworkand thuswastesworker,sknowledge,theJapaneseproductionsystemmakesuseof worker,sexperienceandknowledge・TherefbreitisconducivetoinnovationKenney
&Floridafbundthecoreofthesystemtobetheproductionteam,inwhichwork rolesoverlapandtasksareassignedtomemberworkersandthenreallocatedamong members、Teamsarethebasicmechanismfbrmovingdecision-makingdowntothe shopHoorandsolvingproductionproblems・Ittransfbrmstheextractionofintellec-
tual(andmanual)laborintoasocial,collectiveprocess・Accordingly,itmakesit
possibletoharnessworkers,knowledgeasasourceofvalueatthepointofproduc- tion、Theycalltheseteams``selfmanagingworkteams.,,Also,Japanesemanagers andengineershaveconstantcontactwiththeshopHoor・Thesocialdistances33
FromtheDiffUsionofLeanPmductiontothcHybridizationPerspective:
betweenmanagersandworkersarenarrow、Asaresult,firmsareabletocreatelarge
stocksofknowledgewithintheworkfb1℃es・
AccordingtotheirfieldreseamhonJapaneseaffI1iatedplants,aimedatanswer‐
ingquestionsaboutthetransferabilityandgeneralizabilityofthemodel,automotive plantshadsuccessfilUytransfbrredtheirsystemtotheU.S、Bycomparison,the experiencesofTVassemblyplantshavebeenmixed・KenneysuggeststhatTVtrans‐
plantswerebuiltbefbreJapanesemanagersbecameconfidentoftheirabilitytotrans‐
fbrthesystem(Kenney,1999).Therefbre,Kenney&Florida,sanswertothe questionoftransfbrabilityofthesystemwasaffinnative,butnotunequivocal,
MacDufHeandPilalsofbcusedontheworkorganization,sayingthatthelean productionhasfburspecificfeatures,alldifTerentfrommassproduction:(1)general resources,suchasgeneralpurposemachinesandmulti-skilledworkers,(2)small bufTbrsandlotsizesinplantOperation,(3)decentralizedauthority,and(4)integra- tionofconceptualactivitywithexecutionofproductiontasks(MacDufHe&Pil,
1997:11).Theycalltheworkorganizationunderleanproduction“High-
InvolvementWorkPractices,,andemphasizefiveworkpractice:(1)on-linework
teams,(2)offLlinesmallgroupactivitiesorproblem-solvinggroups,(3)jobrotation,
(4)suggestionprograms,and(5)thedecentralizationofqualitycontroleflbrta Theyconcludedthatthehighperfbrmancerateisachievedthroughtheimplementa‐
tionofsuchworkpractices,combinedwithcorrespondinghumanresourcemanage‐
mentpoliciestosupportit・
TheycomparedautomobilemanufacturingplantslocatedintheUSA,Europe,
Japan,Korea,andSouthAfiPica,assessingtheadoptionofhigh-involvementwork practicesaswellasrelatedhumanresourcesmanagementpolicies、Theyconcluded thatitispossibletoseeatrendofconvergencetowardtheadoptionofsuchwork practicesacrossrCgions・Ontheotherhand,theyfbundadivergenceintheadoption
ofthepracticesacrossandwithincompanies、TheftlctorswhichafTectedthediffiJ-sionanddivergenceofleanproductionwereincreasedinternationalcompetition,
manager,schoices,laborunion,schoices,andgovernmentpolicy・Theyidentified fburdistinctgroups:stableandlean(Japanese-ownedplants),rapidmovementto lean(Europeanandnew-entrantplants),adherencetotraditions(us.-ownedplants inNorthAmerica),andhybrids(assortedplantsfi・omvariouscountries).
AdleranalyzedworkorganizationatJapanese-afTiliatedautomotiveplants,from
theviewpointoforganizationallearning(Adler,1993a,1993b).Hiscontributionwastoclarifythefnctthatworkersontheshopfloorcreateworkstandardsbythemselves,
andhepresentedanewassessmentofTaylorismandbureaucracybyproposmgthe
term``DemocraticTaylorism,,,and``EnablingBureaucracy.,,Hefbcusedhisatten‐tionontheproductionsystem,andparticularlytheworkOrganization,atNUMML ajointventureofGMandToyotaMotor,anddiscoveredimportantfactsthrough interviewswiththeemployees,NonesaidtheywantedtogobacktotheGM‐
Fremontdays、EvencriticsassociatedwiththePeople,sCaucus,whoaremainly dissidentswhoopposeharmoniouslaborrelations,weregeneraUyinfavorofthe system・Workerswereparticipatingindeflningtheworkstandardsbyanalyzing
everydaywork・Helisteddistinctionsintermsofthesettingofworkstandardsbe‐tweenNUMMIandtraditionalmassproductionplants・Underthetraditionalplants,
IndustrialEngineerswhoarenotclosetotheworkmaketheworkstandardThen
thelEstakethesestandardtothefbremanThefbremaninturnredesignsthetask
34
tohisownliking,andpresentsthetaskdesigntotheWorkers、Theworkers,finally,
perfbrmthetaskTheworkerscannotimprovetheprocess・Ontheotherhand,
workersmaketheirownstandardsatNUMMLThissystemcontributestoimprove-
mentsinsafety,theenhancementofmotivation,andhighquality・Heconcludedtbat theproblemofscientificmanagementdoesnotlieintheuseofthetechniquesbutin thewaytheyaremadeTheproblemisthatlEsmakethestandardandcompelthe
workerstofbllowthem・Conversely,asworkersatNUMMIhavethebestobjective understandingofthebestwaytodothejob,theycanarguewithmanagementover standards・Standardizedworkgivesworkerstherighttosetuptheirownjobs、Work-ersthusgainpoweragainstmanagers.(3)
Adlerproposedanewwayofassessingbureaucracybasedonthesamefieldre‐
searchHedefinedthe“enablingbureaucracy.,,AlthoughNUMMIfb1malizedbu- reaucraticOrganization,itputimportanceonconsensusdecision-makingandonmiddle managersexercisingtheirauthoritytostimulateandsupportimprovementactivities・
Whenbureaucracytakesanenablingfbrm,thisdoesnotharmcommitment,Hexibility andinnovation(Adler&Borys,1996).HethencomparedNUMMIwithTMMK
(ToyotaMotorManufacturingKentucky)intermsoftheworkpracticesimplemented,
andproposedalearningeffectaswellasahybridperspective・Althoughbothplants hassimilaritiesinthedomainofworkorganization,individualandorganizational learning,andhumanresourceadministration,TMMKshowedsomewhatlessofa ToyotainHuencethanNUMMIinthedomainofemploymentrelations・TMMKchose moreofaunion-substitutionmodelthanNUMMLTMMK,whichwasconstructed laterthanNUMMI,developedadifTerenthybridpatternfiFomNUMMLWhenit enteredtheU.S,ToyotasoughtwaysofworkingwiththeUAWatNUMMI,and choseaprovenefYbctiveunion-substitutionpolicyatTMMK・Heconcludedthat parentcompaniesinterprettbeiroverseasexpansionsasanorganizationallearning
processandadoptdifYbrentchoicesatthenewerplants(Adler,1999).(4)
TheUniversityofMichigan,sJapanTechnologyManagementProgramstudied thetransfbroftheJapanesemanagementsystemintotheUSA、LikeretaL,Remade
i〃Ameriaz:T7zz"qpm"""gα"d刀、"Vb7mi"gJtZpα"eseMz"αgUme"tSysrems(NY:
Oxfbrd,1999),adoptedtheterm“hybrid"asacommonpointofviewfbrthetransfbr oftheJapaneseManagementSystemstotheU.S、Theyusedtheterm“Japanese ManagementSystem,,torefertotheproductionsystemsandcorporatemanagement practicesfbundinJapanesefirms・ThisisbecausesuccessfUlJapaneseHrmsdonot alwaysfbUoweverycontentoftheToyotaProductionSystem,andmayhavebroader commonmanagementsystems・TheyproposedalayeredmodelofJapanesemanage‐
mentsystems,composedoffburaspects:shop-Hoorproductionsystems,ftlctoryor- ganization&management,corporatesystems,andinstitutionalenvironment・Layer one,theshopfloorproductionsystem,encompasseshardtechnologiesasweUas organizationaltechnologies(workpractices,standardizedworksheets,built-inqual- ity,continuousimprovements,andsofbrth).Layertwo,factoryorganizationand management,includeshumanresourcepractices,suppIierrelations,organizational culture,communication,andlearningprocess・Layerthree,thecorporatesystem,
includesthebusinessandmanagementsystem,supportstafEandunionstructure・
Finally,1ayerfbur,theinstitutionalenvironmentiseverythingoutsidethecorporate system・Thisincludesconsumerprefbrences,thelegalandregulatoryenvironment,
educationsystem,andnationalcultureandvalues、Theyhypothesizethatitiseasiest
35
FromtheDimlsiono「LeanProductiontotheHybridizationPcrspcctive:
totransfbrshopfloorproductionSystems,somewhatmorediffIculttotransfbrthe
widerfactoryorganization,andfarmoredifHculttotransfertheinstitutionallinkages
whichsupportthecorporatesystem
Theyputfbrwardthreetheoreticalperspectivesonhybridizationinthecaseof theinternationaldiffilsionoftheJapanesemanagementsystem,Theysawthese perspectivesascomplementary・ThefirstistheinnovationdifTUsionperspective,
meaningthatthetransferofmanagementsystemsissimilartothedifTiJsionofsocial andtechnicalinnovations、AccordingtoRogers,whosummarizedstudiesonthe difTUsionofinnovations,innovationsaremoreeasilydifTUsediftheyhavethefbIlow‐
ingfeatures:highrelativeadvantage,highcompatibilitywithexistingpractices,low intrinsiccomplexity,hightrialabilityandobservability(Rogers,1983).Butthe JapanesemanagementsystemhasthreefactorsthatmakediffmsionmoredifTicult・
Firstly,itisaradicaldeparturefiDmAmericanmanufacturingmanagement、This radicalnessispartoftheadvantageoftheJapanesesystem,butitreducesitscompati- bilitywithexistingpractices、Secondly,thesystematiccharacterofJapanesemanage‐
mentreducesitscompatibilitywithexistingpractices,reducestrialability,andadds complexity・Finally,thetacitnessoftheknowledgeembeddedintheJapaneseman‐
agementsystemsreducesitstrialabilityandobservability、Thesecondisa structuralistperspective・Inthisperspective,theroleof“context”isreferredto・
Proponentsofthisperspectiveseefburtypesoffbrceswhichshapetheinternational difYUsionofthesystem:competitionamongfirms,theintemationaldivisionoflabor orparent-subsidiaryrelations,specifYcsocietiesorsocietalefiects,andspecificcom‐
paniesandplants・Theinteractionbetweenthesefbrcescreatesacomplexdynamic・
Thus,thetransferofthesystemproduceshybridpatterns・Thethirdisanemergent perspectiveThetransferoftheJapanesemanagementsystemcannotbedesigned,but isemergentinthesenseofanevolutionaryviewofthefirm・Eventhemanagement systemisonlypartlytheresultofplanning,andismoreoftentheresultofopportun- isticexperimentalfbrmsoflearning・Itisdifficulttoimaginehowsuchsystemscan bedeliberatelytrans化rred、Giventhecomplexity,interconnectedness,andtacitness ofsuchsystems,theyareimperfiect・Recipientorganizationshavetheirownunder- standingsofthesystem・Interactionbetweensendersandrecipientsgeneratenew interpretationsofwhatisbeingtransfbrred,whatisnotbeingtransfbrred,andhow thetransferisprogressing・Consideringthesefactors,theprocessoftransfbrseemsto
beoneofemergence(LikeretaL,1999:3-35).(5)5.ConcludingRemarks
LookingbackonthedevelopmentofstudiesregardingthetransfbroftheJapa-
nesesystemtotheUSA,AbernathyfirstputfbrwardtheJapanesemodelasanalter-
nativetomassproduction,basedonahypothesisofde-maturityrelyingonthe perspectiveofdynamicin、ovationSecondcametheLeanProductionperspective,
bytheInternationalMotorVehicleProgramatMIT、WomacketaL,clarifiedthe competitiveadvantagesofleanproductionovermassproduction,andtheyclaimed thatthesystemwastransfbrableTheyalsofbrmulatedatheoryofleanproduction,
separatedfromthetechniquesormethods,whichwasusefillfbrunderstandingthe contentofthesystem・Laterstudieswentontothehybridizationperspective.
36
Researcherswhowerelookingintotheorganizationalaspectsofthesystemfbcused onworkorganizationandhumanresourcesmanagementpolicy・KenneyandFlorida investigatedtheintegrationofmanua1andmentalworkontheshopfloor,andpro‐
posedtheterm“innovation-mediatedproduction.,,TheydiscoveredthatdifYerent hybridpatternswereseenatdifTerentautomobileandelectricplants・MacDufHeand Pilproposedthetelm“high-involvementworkpractices,'andfbundatrendofcon‐
vergencetowardleanproductioninvariousregionsasweUasdivergentpracticesat difYierentfIrmsandplants・Adlerputgreatimportanceintohavingworkersmake workstandardsontheshopHoor,andcalledthis“democraticTaylorism,,and``ena‐
blingbureaucracy.”Hewrotethatenablingbureaucracydoesnotcutcommitment andinnovationHealsopointedoutdifYerentfbrmsofhybridizationattwoToyota plants・LikeretaL,demonstratedthetransferabilityoftheJapanesemanagement systemtotheUSA,andclariHedthatthetransfbrredmanagementsystemswere hybridTheyalsoattemptedtofbrmulatetheoreticalperspectivestoanalyzethe hybridizationofthesysteminenvironmentsdifTerentfromthatofthehomecountry.
Notes
(1)Utterbackexplainedthelbrmationofinnovationdynamics(Utterback,1994).
(2)FriedmanproposedrevivingtheAmericanautomobileindust「ybyadoptingthe JapanesesystemHeusedtheterm“Japanization,,,whichisanexceptionintheU.S・
setting(Friedman,1983).SchonbergerindicatedthattheJapanesep「oductionsystem,
composedoftwofnctors,JITandTQC,wastransfbrabletotheUS.(Schonberger,
1982).
(3)Aflewsupplementarycommentsareneededhere・AdlerexplainedthatatNUMMI theworkersmadetheworkstandardsdirectly、However,accordingtomyresearch carriedoutinMayl996,thesituationisslightIydiffbrent・Japanesemanagerstoldme thatproductionworkersdonotmaketheworkstandar。s・Bothteamleademsandgroup leadersareinchargeo「makingthestandards・However,whenanewmodelislaunched,
apilotteamcomposedofproductionworkersselectedfromtheshopnoorcreatethe standardlnthiscase,productionworkersmakeworkstandardstogetherwithteam leadersandgroupIeaders,ItisimportantfbTworkersthemselvestounderstandtheir jobcontents・AseachworkerhasuniquecharacteristicsandadifY1erentbodysizefrom
others,he/shemightbetemptedtoperfbrmtheworkinhis/herownway・Thiscould causeobstaclestojobrotationandqualityproblems・Therefbre,thestandardizationof workisneeded,andisimplementedthroughdiscussionswithintheteams、Iwasgiven nearlythesameexplanationbyJapanesemanagersatotherJapaneseplants・Therewas onecasewhichHtAdler,sexplanation,namelytheHondaofAmericaManufacturing plantinMarysville,Ohio,whereworkersmadetheworkstandards・Managerssug‐
gestedthattheyusepicturestomakcthetaskeasier・Whatisimportantisnotwhether p「oductionworkersmaketheworkstandarddirectlyWhentheJapaneseproduction systemisadopted,dif化rentprocedurecanbeinstitutionalizedThestandardizationof workenhancesworkers,abilitytolearnandgivesthempowertocontro]workonthe shopfloor.
(4)Ofcourse,noteveryresearcherhadpositiveevaluationsoftheJapanesesystem、For example,Babson,Steveed.,Leα〃リイノb戒:E'?Zpowrme"Zα"dExpノOjm1io〃i〃ZノカCGノb6Qノ AmoI>zdHsZ〃(Michigan:WayneStateUniversityPress,1995)presentedsharplydiffer- entviewsonthesystem:empowermentandexploitation,commitmentandhighinteL sityofworkCriticssometimesomerinterestingissues.
37
FromtheDinUsionorLeanProduclioultoIhcl-IybridizatioI1Pc応pcctivc:
(5)Westneypresentedpersuasiveviewpointlbrunderstandingcross-societalorganiza‐
tionaltrans化rs,byproposingthreegeneralorganizationalperspectives・Heidentifled themfi「omorganization-environmentalrelations、Thethreeperspectiveswere“strategic design,,,“socialconstruct,,,and``politicalperspective.”Hemadepredictionsbasedon eachperspectiveonthelogicoftransfbrandhybridizationAIthoughlfbundhis explanationsvelyinteresting,Iwouldliketoonlymentiononeaspectofhybridization・
Helookedatthreedriversofhybridization:theinteractionoffbreignandlocalpatterns
withintheorganization,imper化ctinfbrmation,andtheinteractionbetweenintemal patternsandkeyelementsoftheenvironment・Withregardtotheinteractionbetween fbrcignandlocalpatte「ns,行omthestrategicdesignperspectWe,hybridizationoccursbecauseofalackofconfbrmitybetweenfbreignand1ocalpatterns・Therearecompet‐
ingpullsbetweentheparento「ganizationalmodelandprevailingloca1modeIs・From
thesocialconstructperspective,thetrans化rofsystemsacrossbordemsalwaysproduces
somethingdifYbrentinthenewsettingBecausethe価「eignpatternsareperceivedand interpreteddifherentlythanathome,hybridizationisarule,Reinterpretationleadsto changesinhowitactuaUyoperates、Fromthepoliticalperspective,thecombinationof lbreignandlocalpatternsconstitutesapotentialarenafb「contendinginterests、PCr example,expatriatesmanagersnndthemselvesfhcingadilemma・Theyhaveasource ofpowerderivedfmmtheirknowledgeortheparentcompany,butcanonlyachieve successintheirpositionsirlocalemp]oyeesaccepttheirpositionandagendaHybridi- zationstrategiesgiveananswertothisdilemma、Inthisway,heproposedpersuasive theoreticalperspectivesonhybridization(Westney,1999).References
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