The purpose of this study was to investigate and describe an organization's transition to a focused factory of the future. This transition entailed broad changes in manufacturing equipment/technology, manufacturing processes, and organizational culture.The findings of the study included:The organization focused one product model rather than focusing their two major product lines simultaneously. The result was new and stronger barriers emerging rather than the cited objective of breaking down barriers. There was a concentrated effort by the local labor union to resist the new changes while maintaining their own cultural identity.Many of the problems which impeded the transition resulted from external sources where the organization had limited control. These problems with external sources were:1. Conflicts with the organization's corporate headquarters who held an opposing interpretation as to the extent to which the organization should focus.2. Costly delays resulting from machine vendors not meeting their delivery dates.3. Time pressures resulting from deadlines administered by the organization's customer.4. Substantial quality problems experienced from a dependence on a single casting vendor.There is a critical need for frequent communications between management and hourly workers during a transition of this magnitude. The hourly workers have less access to information and make interpretations of events based on available information, real or rumored. The hourly workers are dependent on information from management and when events "suddenly" do not occur as expected a negative perception of management results.Many of the hourly workforce responded magnificently to the challenges of moving beyond "pushing buttons" to becoming a thinking and decision-making facet of the organization. Although some hourly workers who had been acculturated at a time when they were "not paid to think" did not respond well to the unsupervised environment, a large number of the workers demonstrated a voraciousness for the opportunity.RecommendationsPrior to initiating a major change in an organization a very detailed and thorough evaluation needs to be conducted of all potential sources of roadblocks to success. This evaluation should include research on organizations who have experienced similar transitions in the past. The planning should include: An assessment of the internal organizational culture.This would include the likelihood of union support even in lieu of a shift in union leadership.An analysis of the costs/benefits of initiating a new product within the existing plant or at a completely new location.A detailed assessment of all vendors with an alternate in case of utilization of one exclusive supplier. A careful assessment of a machine vendor's ability to meet delivery dates and stringent contractual guidelines which would maximize punctual delivery. Prior to initiating the project there needs to be communication and agreement between the organization and corporate headquarters in regards to the specific details of the changes.A thorough research of potential material vendors needs to be conducted in order to ensure a stable vendor who produces a quality product.A careful selection procedure should be developed which enlists individuals who are willing and able to make the transition along with the organization.
| Identifer | oai:union.ndltd.org:BSU/oai:cardinalscholar.bsu.edu:handle/176982 |
| Date | 03 June 2011 |
| Creators | Huston, J. T. |
| Contributors | McElhinney, James H. |
| Source Sets | Ball State University |
| Detected Language | English |
| Format | 156 leaves ; 28 cm. |
| Source | Virtual Press |
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