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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

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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、Hefbrmulatedamodelfbranalyzingtheevolutionaryprocessofinnovation

bothinproducttechnologyand、anufncturingprocesstechnology・Basedonthis

model,hepreciselydefmedthestagnationofinnovationintheAmericanautomobile

industry,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,he

claimedthatinnovationhadstagnatedlnperiodswheninnovationwassta2mant,

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・The

secondpathwasdesirable,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・Onthe

otherhand,Toyota,sproductionsystemwasaleanoperationwithoutwaste・Givmg

productivity,qualityandHexibilityastheprimaryindicatorsofplantperfbrmance,he

presentedtheadvantagesofleanproductionovertraditionalmassproductionplants・

Inl990,WomacketaLpublishedZ1ノieMtJcAj"er/iatChα"gEdjAeリリノbrki,which

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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,Theelimmationof

wastesometimesrequirenewprocesstechnologiesandnewproductconcepts、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、1t

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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・Thesocialdistances

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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).Hiscontributionwas

toclarifythefnctthatworkersontheshopfloorcreateworkstandardsbythemselves,

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

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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

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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

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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

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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,hybridizationoccurs

becauseofalackofconfbrmitybetweenfbreignand1ocalpatterns・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).

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