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Inside Japan:
Agenda
1. Introduction: What is M.E.?
2. System Integration: Necessary & Difficult
3. Intl Comparison of System Integration
Japan = Key role played by M.E.
Europe = Key role played by development
(i.e., product engineering)
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What is M.E.?
Manufacturing Engineering sits between product
development and manufacturing in the value
chain
Roles of M.E.
Set plant layout & production process flow
Establish standard operating procedures
Design production equipment
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Manufacturing Engineering
M.E.
Agenda
1. Introduction: What is M.E.?
2. System Integration: Necessary & Difficult
3. Intl Comparison of System Integration
Japan = Key role played by M.E.
Europe = Key role played by development
(i.e., product engineering)
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Lynchpin
System Integrator
(Photo Sourcehttp://japan.osu.edu/culture_box_program.html)
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Car Door
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Car
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RX-8
(2003)
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Agenda
1. Introduction: What is M.E.?
2. System Integration: Necessary & Difficult
3. Intl Comparison of System Integration
Japan = Key role played by M.E.
Europe = Key role played by development
(i.e., product engineering)
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Development
Manufacturing
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Development
M.E.
Manufacturing
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M.E.
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Why M.E.?
M.E. can occupy a neutral position
Because it neither develops nor manufactures the product
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Tend to see
Customer!
or
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M.E. as Lynchpin
M.E.
D.A. Heller, 2013
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The result
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The result
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The result
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The result
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M.E.
M
In most cases
NO
Way!
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M.E. in Europe
(M)E
new
production
equipment
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Development
+(M)E
Manufacturing
D.A. Heller, 2012
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The result
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The result
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The result
Agenda
1. Introduction: What is M.E.?
2. System Integration: Necessary & Difficult
3. Intl Comparison of System Integration
Japan = Key role played by M.E.
Europe = Key role played by development
(i.e., product engineering)
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Empowerment of M.E. in
Overseas Subsidiaries
To get global optimization, become truly lean, must
strengthen M.E. in the overseas subsidiaries of
Japanese automotive companies
But M.E. is not a natural repository of power and
influence. This is especially true outside of Japan.
Special organizational initiatives needed.
For example in Toyota, Japan:
High % of top management w/ M.E. background
As of 2007, in Toyota City there were more than 8,000
Manufacturing Engineers (called production engineers)
(not including plant-based manufacturing technicians)
D.A. Heller, 2013
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A Long-Term Challenge
More standardization of development needed
Shared priorities facilitate standardization
Getting agreement on what are the right priorities takes
time and effort
Everyone must buy-in to these priorities
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(Keeping them
in M.E. is
even harder)
D.A. Heller,
2012 Business Review, May 2010)
(Cover
of Harvard
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Selected
References
Clark, K. B., & Fujimoto, T. (1991). Product Development Performance, Harvard Business School Press,
Boston, MA.
Higashi, H., & Heller, D.A. (2012). Thirty Years of Benchmarking Product Development Performance:
A Research Note. The University of Tokyo Manufacturing Management Research Center, Discussion
Paper Series, No. 395. http://merc.e.u-tokyo.ac.jp/mmrc/dp/pdf/MMRC395_2012.pdf
Koike, K. (2008). "Kaigai Nihon Kigyo no Jinzai Keisei", [Human Resources Development of Japanese
firms overseas], Tokyo: Toyo Keizai Shinbunsha (in Japanese).
Marinov, M. & Heller, D.A. (2013) Manufacturing Management Research Center, F-202 Discussion
Paper. http://merc.e.u-tokyo.ac.jp/mmrc/dp/pdf/MMRC431_2013.pdf Todays focus
Shibata, H., (2009), "A comparison of the roles and responsibilities of manufacturing engineers in Japan
and the United States", The International Journal of Human Resource Management, Vol. 20, No. 9, pp.
18961913.
Sobek, D.K., II (2006) System-Level Design: A Missing Link? International Journal of Engineering
Education, vol. 22, no. 3, pp. 533-539.
Whitney, D.E., Heller, D.A., Higashi, H., & Fukuzawa, M. (2007) Production Engineering as System
Integrator? A Research Note based on a Study of Door Engineering and Assembly at Toyota Motor
Corporation Manufacturing Management Research Center, F-169 Discussion Paper. http://merc.e.utokyo.ac.jp/mmrc/dp/pdf/MMRC169_2007.pdf Todays focus
Whitney, D.E. (2008) Design and Manufacturing of Car Doors: Report on Visits Made to US, European
and Japanese Car Manufacturers in 2007 Manufacturing Management Research Center, F-202
Discussion Paper. http://merc.e.u-tokyo.ac.jp/mmrc/dp/pdf/MMRC202_2008.pdf
Womack, J.P., Jones, D.T. & Roos, D. (1990), The Machine that Changed the World: The Story of
Lean Production, Rawson Associates, New York, NY.
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Thank you!
Q&A
D.A. Heller, 2012
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Appendix
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Shibata (2009)
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Micro-level Summary:
Distribution of Manufacturing Engineering Tasks
Focus on
analytical tasks in
the phase
(Europe)
(Japan)
Key: Blue indicates holder of overall responsibility; Lead role means coordinate, strongly influence
decision making, and execute the majority of the tasks in the phase; Informational support means focus
on providing feedback from the point of view of the line operators; At both Supplier E and Supplier J, ME
provides various forms of technical and informational assistance to MT in the production preparation
phase.
Figure Source: Marinov & Heller (2013), p. 18; see also, Shibata (2009)
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Method
development
ME
ME - manufacturing engineers
MT - manufacturing technicians
M. Marinov & D.A. Heller, 2013
Production
preparation
Production
improvement
MT
Shibata (2009)
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Method
development
Production
preparation
Production
improvement
ME
ME - manufacturing engineers
Shibata (2009)
M. Marinov & D.A. Heller, 2013
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1. Overlapping or not
Compared to the U.S. companies,
3. Localized or not
the Japanese companies exhibited
downstream personnel who are
US: MT localized to plant
much more heavily involved in
Japan: Inter-divisional
upstream processes
tasks and functions of MT
2. Hierarchical or not
Japan Horizontal relationship between ME and MT
US Vertical relationship between ME and MT
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Middle-up-down
Management
Middle-Up-Down figure
(Source: Nonaka
& Takeuchi, 1996,
Knowledge Creating
Company)
1996191 56
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1996192 57
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/West
/Japan
top
top
middle
middle
bottom
bottom
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/West
/Japan
top
top
middle
middle
bottom
bottom
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/West
/Japan
boss
boss
worker worker
worker worker
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/West
/Japan
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Whats a lynchpin?
Pin inserted through an axletree to hold a
wheel on
(Source: http://www.thefreedictionary.com/lynchpin)
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(s: http://farm1.static.flickr.com/14/18180390_cab6aad207.jpg
http://www.disabledparents.net/imagesres/cribpics/hasp-linchpin-pull-rev.JPG)
D.A. Heller, 2013
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A lynchpin
pin inserted through an axletree to hold a
wheel on
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