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LEARNING
FACTORIES
PALGRAVE STUDIES
IN DEMOCRACY,
INNOVATION, AND
ENTREPRENEURSHIP
FOR GROWTH
The Nordic Model
of Manufacturing
Halvor Holtskog,
Elias G. Carayannis,
Aris Kaloudis,
Geir Ringen
Palgrave Studies in Democracy, Innovation,
and Entrepreneurship for Growth
Series Editor
Elias G. Carayannis
The George Washington University
Washington, District of Columbia, USA
The central theme of this series is to explore why some areas grow and others
stagnate, and to measure the effects and implications in a trans-disciplinary context
that takes both historical evolution and geographical location into account. In other
words, when, how and why does the nature and dynamics of a political regime
inform and shape the drivers of growth and especially innovation and entrepreneurship?
In this socio-economic and socio-technical context, how could we best achieve
growth, financially and environmentally?
This series aims to address such issues as:
• How does technological advance occur, and what are the strategic processes
and institutions involved?
• How are new businesses created? To what extent is intellectual property
protected?
• Which cultural characteristics serve to promote or impede innovation? In
what ways is wealth distributed or concentrated?
These are among the key questions framing policy and strategic decision-making
at firm, industry, national, and regional levels.
A primary feature of the series is to consider the dynamics of innovation and
entrepreneurship in the context of globalization, with particular respect to emerging
markets, such as China, India, Russia, and Latin America. (For example, what are
the implications of China’s rapid transition from providing low-cost manufacturing
and services to becoming an innovation powerhouse? How do the perspectives of
history and geography explain this phenomenon?)
Contributions from researchers in a wide variety of fields will connect and relate
the relationships and inter-dependencies among (1) Innovation, (2) Political
Regime, and (3) Economic and Social Development. We will consider whether
innovation is demonstrated differently across sectors (e.g., health, education,
technology) and disciplines (e.g., social sciences, physical sciences), with an emphasis
on discovering emerging patterns, factors, triggers, catalysts, and accelerators to
innovation, and their impact on future research, practice, and policy.
This series will delve into what are the sustainable and sufficient growth
mechanisms for the foreseeable future for developed, knowledge-based economies
and societies (such as the EU and the US) in the context of multiple, concurrent
and inter-connected “tipping-point” effects with short (MENA) as well as long
(China, India) term effects from a geo-strategic, geo-economic, geo-political and
geo-technological set of perspectives.
This conceptualization lies at the heart of the series, and offers to explore the
correlation between democracy, innovation and growth.
Learning Factories
The Nordic Model of Manufacturing
Halvor Holtskog Elias G. Carayannis
Department of Manufacturing School of Business
and Civil Engineering George Washington University
Norwegian University of Science Washington, District of Columbia, USA
and Technology
Gjøvik, Norway Geir Ringen
Department of Manufacturing
Aris Kaloudis and Civil Engineering
Department of Industrial Economics Norwegian University of Science
and Technology Management and Technology
Norwegian University of Science Gjøvik, Norway
and Technology
Gjøvik, Norway
1 Introductory Chapter 1
6 Facilitative Management103
8 Conclusion149
References157
Index167
v
List of Figures
vii
List of Tables
ix
CHAPTER 1
Introductory Chapter
Abstract This chapter aims to provide deeper insight into how a m odern
and sophisticated management of employees plays an important and—in
our view—key role for the successful reindustrialization of the Western
world. There are important lessons to learn from high-cost countries that
successfully compete in the global marketplace. In such contexts, the re-
combination of tacit knowledge, people, competences and culture to cre-
ate effective and efficient automated production is indeed essential.
Introduction
In both the USA and Europe, there are currently huge efforts to reindus-
trialize economies after decades of neglecting industry as the most impor-
tant economic factor for society. Such a phenomenon is the starting point
of this investigation. Specifically, Japanese ways of production have often
been studied and—to some degree—copied by American and European
firms whereby ‘Lean’ has become the de facto standard for effective and
efficient production. Recently, however, new initiatives have emerged.
Industry 4.0 is one of these, and it has a strong technological focus. It
involves censors which gather data from every step of the automated pro-
duction process, identifying each nut and bolt is prerequisite, as is the
usage of big data. However, little attention is given to people and the
knowledge-creation process.
This book aims to provide deeper insight into how the people-aspect
plays an important and—in our view—key role for the successful reindus-
trialization of the Western world. It argues that there are important learn-
ing points from high cost countries that successfully compete in the global
marketplace. In such contexts, the re-combination of tacit knowledge,
people, and culture to create effective and efficient automated production
is indeed essential and visible.
The Norwegian labor market and work organization are similar to
those of Denmark and Sweden, its Nordic neighbors. This socio-economic
organization is often labeled ‘the Nordic model,’ the result of four key
institutionalized societal mechanisms:
three distinct levels of doubt exist: perceptual illusion, the dream problem,
and the deceiving God (‘Descartes: God and Human Nature,’ 2013).
‘Perceptual illusion’ means that our senses can play with us. Magicians are
experts in illusion and the audience becomes astonished when impossible
things happen on stage. In everyday life, our senses play a vital role in how
we perceive things, but many times what we perceive turns out to be
something else, such as often the case for first impressions. ‘The dream
problem’ refers to the boundary between a dream-state and consciousness
that can be difficult to separate. Psychology has proven that the human
brain fills in blank spots and creates patterns. These pattern recognitions
are well developed (Lehrer, 2012). However, this does not mean that the
patterns, or the creative process, produce something close to what many
regard as reality. ‘A deceiving God’ in Cartesian philosophy invites us to
doubt our traditional beliefs. In his case, it was religion. Systematic doubt
challenges existing knowledge and makes us rethink initial thoughts. In
this way, new aspects are discovered. With a system perspective, or subsys-
tems within subsystems, such doubt drives the investigation by assuming
the conclusions are wrong which therefore creates the motivation to test
them. In social science, systematic doubt is pursued in triangulation
because it is void of laboratory control that allows us to refine the range.
Therefore, the alternative is to look at something from various angles and
hope to discover something about it.
Flick pointed out that qualitative research often focuses on multi-
methods (Denzin & Lincoln, 1994; Flick, 1998, p. 229). The metaphor
triangulation comes from military usage and naval navigation where mul-
tiple reference points were used to pinpoint, through geometry, the exact
position of an object (Smith & Kleine, 1986). Thus, ‘[t]he combination of
multiple methodological practices, empirical materials, perspectives, and
observers in a single study is best understood, then, as a strategy that adds
rigor, breadth, complexity, richness, and depth to any inquiry’ (Flick, 1998,
p. 231). One common misconception is that triangulation is used in social
science to check and validate studies. Indeed, achieving consistency across
data sources or methods can be useful, although Patton (2002) argued
that inconsistencies reveal opportunities to uncover deeper meaning in the
data. The same argument can be found in Miles and Huberman’s book,
Qualitative Data Analysis (Miles & Huberman, 1994, pp. 266–267).
Another support for the argument of uncovering deeper meaning in
the data is offered by Yeasmin and Rahman (2012). These authors point
out that triangulation tends to support interdisciplinary research, where
theories from different disciplines help deepen our understandings,
6 1 INTRODUCTORY CHAPTER
and brings deeper insight into the complex process of creating knowledge
and learning in an industrial setting. Precisely, it is like looking into a kalei-
doscope and finding new pictures of changing facets and colors.
Therefore, the argument is a combination of political economy, social
organization, and cultural systems (classification, worldviews, ideologies,
and myth) together make a framework for the analysis of a human system.
However, the multi-method perspective here is limited to organizational
behavior and technology management. Therefore, this book investigates
organizational behaviors with multi-causalities within multi-dimensional
nested systems, guiding the theoretical positions.
Theoretical Foundation
Manufacturing industries have created many reforms for maintaining and
developing their efficiency and effectiveness. Both quality and Lean2 sys-
tems have lots of initiatives and tools for formalizing the work method
used at different levels in the organization. Further, they also have initia-
tives and tools for tapping into the tacit knowledge of the workers, moti-
vating continuous improvement. Ideally, workers should continually come
up with ways of improving work to develop best practice by formalizing
how a task is done, for example, with one-point lessons. These are distrib-
uted throughout the company when changed. In this way, the company’s
operations become more efficient and effective throughout the years.
Concurrently, these reforms also implement overall operational systems
such as just-in-time, statistical process control, and so on. Such systems
demand specific structures and prescribe distinct methods to gain overall
results. Klein (1989, 1991) places these arguments together in two arti-
cles, where the loss of autonomy regarding performance and method are
central points. These losses are scaled toward individuals and teams.
However, the companies also loose autonomy of decisions. For instance,
just-in-time set the production pace for all of the subcontractors delivering
parts. This means that scales of autonomy, performance, and method can
be used to describe development in a bigger picture. In this book, Fig. 1.1
guides the argumentation:
The four quadrats represent different ways of conducting work or doing
business. Ideally, a company can decide its own performance, for instance,
how many products it produces and of what quality, and which production
method. However, in reality the company serves a market, and it is the mar-
ket that decides the volume and/or level of quality alongside its competitors.
8 1 INTRODUCTORY CHAPTER
Autonomous Autonomous
performance, performance
rigid method and method
Rigid
Rigid method
performance,
and
autonomous
performance
method
Data Usage
Data were gathered from two case studies including formal documents,
in-depth interviews, participation, observations, and surveys. Different
approaches to the case studies have been followed. Case 1 (C6) is the main
study where the research team tried to facilitate different changes and fol-
lowed a specific development project in detail over a period of two years.
Meanwhile, Case 2 (C3) is the secondary case where another researcher
initiated some of the change processes. These change efforts have been
primarily in the quality department and were therefore not included in this
book. In C3, data were gathered by talking to various people and looking
at some internal data from systems, serving as the validation tool and
DATA USAGE 9
time before the contract was achieved, and followed it to the planning of
the industrialization phase. Sitting in many of the project meetings, both
internally and externally, the quality expert in the team was also used as
regular help in the project.
The observation of change actions6 was taken out of the participation to
demonstrate that we tried to change in our effort via action research. We
attempted to simplify the FMEA process and form, which C6 thought was
a very good idea and took charge of with the quality expert as a consultant.
We further tried to make the project’s progress and problem-solving more
visual. Toyota has something called the Obeya room (big room) where
everything important to a project is put up for every participant to see. We
tried this at C6, but there were no rooms to do this so we settled for a mov-
able whiteboard, and brought it to every meeting. The idea was that we
should start updating the whiteboard and gradually leave the responsibility
to the company. However, in practice, this did not fully work, as we were
the only ones updating the board. And, upon discussing its value several
times with no update actions, the idea was abandoned.7 Another idea was
the A3 form, or focus sheet as we called it (Shook, 2008; Sobek & Smalley,
2008). This followed the same idea of visualizing the problems, thus mak-
ing it easier to contribute to the problem-solving process. Based on data
from specific parts of the development project, the research team produced
several A3 forms demonstrating the technique. In some ways, it was
adapted, such as when the project manager made some forms to show his
colleagues about a specific problem, although the majority did not use
them. The observation of change actions became much more focused on
when the financial crisis struck and the organizational changes started.
Volunteerism or ‘dugnad’ was partially prominent. The new leadership
wanted to withdraw C6 from the research project, but then the developers
stepped in and told management about the value of the research team. An
agreement was reached about further participation in the project of devel-
opment of parts to the North European car manufacturer.
In-depth interviews were conducted for two purposes: (a) to familiarize
with the employees in their professional work and workplace, and (b) to
attain insight into specific problems. When asked, everyone took time off
to speak with us, and these conversations could sometimes last for much
longer than planned due to long technological explanations. There were
also some people who travelled a lot and were seldom in the office and
getting them to talk required more creative approaches. For example,
there is a travel office that coordinates travel at the Raufoss Industrial
VALIDITY 11
Park, and one of its services is car rental to-and-from the airport which
takes approximately 1.5 hours. We were able to coordinate our travel in
the same rental car.
Participation represents taking an active part in discussions and
meetings, as well as widening the research team’s knowledge. In-depth
interviews were also used to check and clarify our understandings of the
technological details. When the financial crisis struck the case compa-
nies, a new opportunity emerged for writing public-funding applications
of R&D projects. Writing these meant that, as a research team, we had
even more time to talk with the experts, obtaining more insight into
what they believed were cutting-edge technologies and why. This con-
tributed to facilitating a deeper understanding of the companies, espe-
cially regarding the inner—or more hidden—logic of the engineering
culture and its tools.
A network survey was conducted of explaining the rules element from
which we produced a networking survey. We collected collaboration data
by asking the project members who they talked with and how often. In
addition, we mapped which external people arose in this exercise, as well
as their colleagues and specialties. What is presented in this book is a sim-
plification of these data. Nevertheless, during this phase many contacts
between the North European car manufacturer as the customer and C6
occurred. The project leader and the sales and marketing manager at C6
verified the chart. The findings were presented to the sales and marketing
manager, and the development manager at C3. C3, though, had a slightly
different system with onsite engineers8 who stay in constant direct contact
with the customer, but once a project is under way, the contact patterns
were very similar to that of C6.
Investigations were first characterized by getting to know the various
systems, standards, and formal documentation at C6. Lots of formal docu-
ments were read, and a pattern gradually emerged that did not correspond
with the formal systems. All the formal documents, notes, in-depth inter-
views, and forms were gradually built in a database using NVivo9 which
served as a repository for coded data used for analysis and reflections.
Validity
Guba and Lincoln (1989) frame validity as a matter of both credibility and
authenticity, defining credibility as ‘the idea … of isomorphism between con-
structed realities of respondents and the reconstructions attributed to them’
12 1 INTRODUCTORY CHAPTER
Persistent Observation This adds depth to the scope that prolonged engage-
ment affords. The research team had access to quality and management
systems, as well as to the network disks where temporary files and forms
were placed during their completion process. These formal systems meant
that we could check assumptions and statements from the participants in
the case companies. We also had available data from the operation’s man-
agement logging system which allowed us to establish the success of each
production process and enabled us to go back many years. The manual
paper-based achievement was subjected to scrutiny in some of our investi-
gations. As for observation, we participated in many of the various project
meetings in the development of parts to the North European car manufac-
turer. Further, as the research team consisted of four people, observed phe-
nomena could be discussed and reflected upon from different angles.
Peer Debriefing The purpose here is to test the findings with someone
directly involved in the situation and to highlight tacit and implicit infor-
mation. The research has accomplished this in various ways. First, supervi-
sors and the staff at EDWOR10 have been a great help by indicating the
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