Exploring UK Lean Diffusion in the Period 1988 to Donna Elizabeth Samuel

Exploring UK Lean Diffusion in the period 1988 to 2010 by Donna Elizabeth Samuel A Thesis Submitted in Fulfillment of the Requirements for the Degree of Doctor of Philosophy of Cardiff University Logistics and Operations Management Section of Cardiff Business School Cardiff University October 2011 UMI Number: U584548 All rights reserved INFORMATION TO ALL USERS The quality of this reproduction is dependent upon the quality of the copy submitted. In the unlikely event that the author did not send a complete manuscript and there are missing pages, these will be noted. Also, if material had to be removed, a note will indicate the deletion. Dissertation Publishing UMI U584548 Published by ProQuest LLC 2013. Copyright in the Dissertation held by the Author. Microform Edition © ProQuest LLC. All rights reserved. This work is protected against unauthorized copying under Title 17, United States Code. ProQuest LLC 789 East Eisenhower Parkway P.O. 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TABLE OF CONTENTS LIST OF FIGURES iii LIST OF TABLES iv LIST OF ABBREVIATIONS V ACKNOWLEDGEMENT vi ABSTRACT vii Chapter 1 Introduction 1 1.1 Background and Motivation for the Study 1 1.2 Subject of the Study 1 1.2.1 What (is the subject of the research)? 2 1.2.2 Why (is the Diffusion of Lean Important)? 7 1.2.3 How Conceptually (will the research be conducted)? 8 1.2.4 How Practically (will the research be conducted)? 10 1.3 Scope and Boundaries of the Study 10 1.4 Structure of this Thesis 11 Chapter 2 Core Literature Review 13 2.1 Defining and Describing Lean 13 2.2 Lean as a Generic Representation of Toyota Production System 20 2.3 Lean as a Best Practice Process Improvement Methodology 27 2.3.1 Six Sigma 29 2.3.2 Theory of Constraints 33 2.3.3 Systems Thinking 36 2.4 Lean as a Movement 40 2.5 Lean as a Body of Literature 50 2.5.1 Criticisms of Lean 54 2.6 Chapter Review 60 Chapter 3 Background Literature Review 62 3.1 Diffusion of Innovation Literature 62 3.1.1 Heritage of Diffusion of Innovation Research 65 3.1.2 Diffusion of Innovation Theory 68 3.1.3 More Recent Contributions to Diffusion of Innovation Theory 76 3.2 Management Fashions and Fads Literature 78 3.2.1 Management Fashions and Fads Theory 81 3.3 Synthesizing the Core and Background Literatures 96 Chapter 4 Focal Literature Review 99 4.1 Focal Literature 99 4.2 Chapter Review 111 Chapter 5 Research Methodology 113 5.1 Research Paradigms 114 5.1.1 Critical Realism 117 5.1.2 The Researchers’ Philosophical Stance 119 5.2 The Research Approach 120 5.2.1 The Exploratory and Qualitative Aspect 120 5.2.2 The Process Aspect 122 5.2.3 The Role of Theory 124 5.3 Research Design 125 5.4 Research Execution 128 5.4.1 Lean Publications Database 128 5.4.2 Expert Interviews 132 5.5 Strengths and Weakness of the Research Design and Execution 139 5.5.1 Design Strengths 139 5.5.2 Design Weaknesses 142 5.6 Chapter Review 144 i Chapter 6 Discussion of Findings 146 6.1 Discussion of Findings (RQ1) 146 6.2 Discussion of Findings (RQ2) 156 6.3 Discussion of Findings (RQ3) 162 6.4 Discussion of Findings (RQ4) 179 6.4.1 Influencing Factor 1: The Promotion of Lean 179 6.4.2 Influencing Factor 2: The Empirical Foundations of Lean 185 6.4.3 Influencing Factor 3: The Simplicity and Visibility Attributes of Lean 186 6.4.4 Influencing Factor 4: A Practitioner Response to Financial Pressures 188 6.4.5 Influencing Factor 5: Networking 190 6.4.6 Influencing Factor 6: Labour Mobility 191 6.4.7 Influencing Factor 7: Isomorphism 193 6.5 Chapter Review 194 Chapter 7 Evaluation of Background Literature 198 7.1 Evaluation of Findings Related to Diffusion of Innovation Literature 198 7.2 Evaluation of Findings Related to Management Fashions and Fads Literature 205 Chapter 8 Conclusions and Contributions 214 8.1 Conclusions from the Study 214 8.1.1 Innovation Specific Factors 215 8.1.2 Context and Timing Factors 218 8.1.3 Promotional Factors 219 8.1.4 Adopter Factors 220 8.2 Contributions and their Significance 222 8.2.1 Contribution to Knowledge 224 8.2.2 Practical Contribution 225 8.2.3 Personal Contribution 227 8.3 Limitations of the Study 228 8.4 Areas for Further Research 230 BIBLIOGRAPHY 233 APPENDICES 276 LIST OF FIGURES Figure Number and Title Page Figure 1 Watson’s ‘What, Why How’ Framework for Research Design 2 Figure 2 Positioning Lean Relative to Other Innovations 5 Figure 3 Conceptual Framework for Organising the Literature 9 Figure 4 History of Support for the UK Automotive Sector over the Last Three Decades 44 Figure 5 Variables Determining the Rate of Adoption 74 Figure 6 Management Fashion Setting Process 82 Figure 7 Theoretical Perspectives on Diffusion and Rejection 83 Figure 8 Lifecycle of Management Fashions and Fads 89 Figure 9 Enhanced Version of the Conceptual Framework for Organising the Literature 98 Figure 10 Hypothetical Diagram of a Toyota Production System/Lean Diffusion Model 101 Figure 11 Interpretation of Watson’s Framework for the Purpose of this Study 113 Figure 12 Research Design 126 Figure 13 Formation of the Lean Publications Database 129 Figure 14 Number of Publications on Lean (1988-2009) 164 Figure 15 Publications on Lean by Type (1987-2009) 166 Figure 16 Pre and Post 2000 Publications by Sector 167 Figure 17 Informant 1’s Perceptions of Lean Diffusion 170 Figure 18 Representation of Lean Diffusion over Time 196 Figure 19 Diffusion of Innovation Model of Determinants of Diffusion 199 Figure 20 Theoretical Framework for the Diffusion of Lean 215 LIST OF TABLES Table Number and Title Page Table 1 Lean Definitions/Brief Explanations 14 Table 2 Publications and Events Leading up to the Emergence of Lean 22 Table 3 Comparing Total Quality Management, Six Sigma and Lean 32 Table 4 Complementarily of Lean and Six Sigma 33 Table 5 Different Practices within Theory of Constraints and Lean Concepts 36 Table 6 Contributions to General Systems Theory 37 Table 7 Evolution of Lean Movement 42 Table 8 Sectors Included in the Department of Trade and Industry Adaptor Programme (1996 to 45 2006) Table 9 Summary of Diffusion of Innovation Research Traditions and their Contributions 65 Table 10 Types of Diffusion of Innovation Research 68 Table 11 Main Concepts within Innovation Diffusion Theory 68 Table 12 Four Models of Innovation Diffusion 76 Table 13 Bandwagon Theories, Assumptions and Effects 84 Table 14 Life-Cycle of Management Fashions and Literature Patterns 88 Table 15 Grint’s Typology of Approaches to Management Fashions 90 Table 16 Sturdy’s Typology of Perspectives on Management Fashions 91 Table 17 Role of Intermediary Groups in the Development of Management Fashions 94 Table 18 Characteristics of the Core and Background Literatures 97 Table 19 Rhetorical Devices and Their Manifestation In The Machine 103 Table 20 Difference and Similarities in Service Processes and Manufacturing Processes 107 Table 21 Public Sector Lean Applications 109 Table 22 Key Contributions on the Diffusion of Lean 111 Table 23 Main Research Paradigms 115 Table 24 Principles of Critical Realism 118 Table 25 Ontological Assumptions of the Realist View of Science 118 Table 26 Common Features of Qualitative Research and their Application in this Study 121 Table 27 Guiding Principles for Conduct in Qualitative Research 122 Table 28 Variance versus Process Approach 123 Table 29 Five Internally Consistent Guiding Assumptions for Conducting Processual Research 124 Table 30 Online Database of Lean publications 130 Table 31 Main Factors Determining BSP Designation as Academic, Trade or Magazine 131 Table 32 Key Terms Used in the Formation of the Lean Publications Database 132 Table 33 Brief Profile of Interviewees and Reasons for Selection 133 Table 34 Interview Structure and Content 136 Table 35 Advantages and Disadvantages of Recording Interviews 138 Table 36 Research Design Evaluated against Criteria of Trustworthiness 140 Table 37 Research Design Evaluated Against Criteria of Authenticity 140 Table 38 Research Design Evaluated against Denzin’s Triangulation Classification 141 Table 39 Research Design Evaluated against Previous DOI Research 142 Table 40 Conceptualisations of Lean 147 Table 41 Perceived Benefits and Failings of Lean and other Organisational and Managerial 158 Innovations Table 42 Five Attributes of an Innovation 159 Table 43 Summary Table of Perceived Innovation Attribute Scores 160 Table 44 Publications and Events Shaping Lean Diffusion 162 Table 45 Summary of Main Findings

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