How business works

248 249HOW SALES AND MARKETING WORKS
Information management

14% Digital dashboard

the increase Displays regularly updated business results using customized graphics.
in sales per
employee if TRACKING EMAIL CAMPAIGN YES
data usability This dashboard tracks the percentage of people who open an email, NO
is improved click on a website, and make a purchase on different days of the week. OPENS
by 10%
DAYS 50% CLICKS
Retrieve and analyze
Mon PURCHASES
Staff can fetch data to answer Tue
specific questions about what is Wed
happening in the company. Thu
Fri
SPREADSHEETS Sat
Form primary BI Sun
tool to display data
(basic or advanced) Mon
Tue
OLAP CUBES Wed
Online analytical Thu
processing cubes Fri
enable 3-D analysis Sat
of three variables Sun
on spreadsheet
Mon
DATA MINING Tue
Allows the sifting of Wed
data to find patterns Thu
and relationships Fri
Sat
REPORTING Sun
TOOLS
Help users 58%Actual sales: $4,700,000
develop and
produce reports Expected sales: $8,125,000

TRACKING SALES 40% 60%
This dashboard 80%
shows the sales a 20%
company actually 0% 100%
makes as a
percentage of
expected sales.

Business analytics

More cutting-edge than business intelligence (BI), business
analytics (BA) allows advanced statistical analysis of data,
which is used to help make future business decisions.

How it works that analyze current and past data, Predictive modeling
BA allows businesses to forecast
BA takes a scientific approach with a high degree of confidence. Software program that predicts
to interpreting information. BA can be applied on a macro patterns of behavior and the
Businesses use BA’s advanced level to get a broad view of future likelihood of specific sets of
software tools to analyze business performance and on a customers, or even individuals,
information about past or current micro level to assess, for example, making a purchase.
trends and behavior to predict a the likelihood of individuals in
future scenario. Unlike business niche markets making purchases.
intelligence or predictive analytics

Business analytics process 93%

A skilled analyst interprets the raw data using of IT executives
BA tools. The results influence the business in Brazil say
actions that will be taken in the future. that their
business could
BUSINESS INTELLIGENCE be improved
AND BUSINESS ANALYTICS by using big
data analytics
The example of a 5 percent sales dip shows how BI and or intelligence
BA can be used to examine and understand the situation.
Business intelligence

❯ Type of data investigation Results reveal past and
current event in the business.

❯ Questions answered What has happened in the
business in the past and what is happening currently?

❯ Tools used Reporting, dashboards, scorecards,
online analytical processing (OLAP)

Business analytics

❯ Type of data investigation Examines past event in
the business, and applies the patterns discovered to
a future scenario.

❯ Questions answered Why did it happen? Will it happen
again? What can we do to stop it from happening again?

❯ Tools used Statistical analysis, data mining, pattern
matching, predictive modeling

250 251HOW SALES AND MARKETING WORKS
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Data visualization DATA USEFULNESS

Formulation of graphs depicting Some data is more useful than
the results of data analysis; other data; value is determined by
graphs may rank data, group the extent to which marketers can
common attributes, and compare use it to make confident forecasts.
relationships. Methods of interpreting data are
increasingly sophisticated.
Pattern matching
Predictive analytics
Process of trawling through large
quantities of data to find patterns Program that conducts
between variables, which can be advanced analysis of data
applied to other sets of data. to forecast future outcome

Data mining Monitoring

Use of computerized processes Process that uses software
and software programs to find to show what is currently
relevant patterns in large sets happening in a business,
of data. providing real-time results
to help key operations
In Out make decisions

Raw data Analysis Statistical analysis

This includes company records Software tools are used to Software that organizes and
(past and current customer data process and study raw data. investigates every piece of
and transaction histories) and Analysts interpret results and relevant data and interprets
external data (economic, trade, make forecasts that help future it to show trends and patterns
and industry reports). business decisions.
Reporting

Method that draws on
historical data to provide
a general overview, revealing,
for example, how the business
performed in a given year

Marketing and IT

The rise of digital marketing strategies means that marketers are
working more closely with IT specialists to develop the best ways
of launching and managing online publicity campaigns.

Convergence of marketing and IT

Communicating with customers online has become a vital part
of many businesses. As a result, marketing relies so much on IT
that in some companies marketing teams spend more money
on technology than their IT departments do.

Areas of overlap

Digital marketing ➤➤

Developing a technology program➤
for publicity campaigns➤
➤
Real-time transactions ➤
➤
Installing a system for recording and tracking
online sales as they happen

Big data ➤

Marketer Locating key statistics from vast amounts of online
information to improve marketing
Must grasp
technology required Data analytics
to execute and track
online campaigns. Using advanced tools to gather and analyze data
for developing future marketing strategy
Mobile technology ➤

Understanding and keeping up to date with advances
in mobile applications and e-commerce potential

Data storage ➤

Building infrastructure and software for storing and
retrieving sales, campaign, and customer history

Social media ➤

Developing the best methods for increasing
online traffic via social media channels

Tracking ➤

Following a customer through
the online engagement and

sales process

252 253HOW SALES AND MARKETING WORKS
Information management

How it works technology. This has led to an increasing overlap
between the marketing and IT departments, and to
Marketers need to know how to use technology to the emergence of a new hybrid professional
increase revenue. At the same time, chief information role—the marketing technologist (see below).
officers (CIOs) are adapting to changes in external

IT person 78% NEED TO KNOW

Must find or develop of marketing ❯ MarTech Annual business
software tools to executives conference that focuses on
implement and believe that overlap of marketing strategy
manage online digital strategies and technology
campaigns. will transform
marketing ❯ Actionable metrics
by 2020 Measurement of campaign
results which enable businesses
to make informed decisions

❯ Vanity metrics Measurements
of campaign results that appear
positive but are not meaningful

❯ Growth hacking Low-cost
online marketing techniques,
such as using social media to
improve sales

RISE OF THE MARKETING TECHNOLOGIST

Online marketers rely on software to monitor and analyze campaigns, generate
content, and extract data. The job of the marketing technologist, who has
knowledge of both marketing and IT, requires a broad knowledge base.

WEBSITE

ARCHITECTURE MARKETING

SOFTWARE SOFTWARE

PROGRAMMING

DATA AND SOCIAL AND
ANALYTICS MOBILE

PLATFORMS

IT CONTENT
OPERATIONS MARKETING

AND SEO

Collecting
consumer data

Capturing key data is a priority for any business seeking to understand

the marketplace. However, the task requires the use of innovative

strategies to circumvent consumer sensitivity about privacy issues. Surveys

How it works Collecting data to create Gather customer
consumer profile feedback via
There are a number of methods email, text, or
companies use to collect customer Digital marketing and e-commerce have mail, and
data. When there is contact between a accelerated the rate at which customer face-to-face
customer and the company, marketers information is gathered. Some methods
can use the opportunity to gather as require the customer’s input, such as questionnaires.
much information as possible. This questionnaires that appear online. Others,
might happen at the point of sale in a such as website tracking, are possible
store or online, where marketers are without the need to contact the customer.
able to observe customer behavior.

Marketers may also choose to solicit

information directly by asking their

customers to fill in registration forms

and conducting telemarketing calls Observations
or customer surveys.

Study customer’s
behavior while they
shop in a store or online.

WARNING Customer
research
Data collection errors
Conduct research on existing
❯ Barraging Using a customer’s data customers or on those who
to bombard them with information fit the customer profile.
on products viewed or sites visited
Contact center
❯ Overlooking technical flaws
Failing to integrate apps properly, Monitor customer
leading to inconsistency (and errors) calls and store data
in collecting customer data on preferences and
purchase history.
❯ Using only automated systems
Neglecting the opportunity to
strengthen relationships with
customers by communicating
with them personally

254 255HOW SALES AND MARKETING WORKS
Information management

Social media 58% TECHNOLOGY AT
THE CHECKOUT
View customer’s of marketers
profile information could link data In this technological age, businesses have
on social media. to an individual the means to learn about their customers without
customer bombarding them with questions. Retailers, for
by 2012 example, typically use three methods in stores
to capture information about the customer.

loyalty card Loyalty program
loyalty card
A company may collect
information by inviting
customers to register for
a loyalty program that
offers an incentive. A
loyalty program also
helps track customer
preferences.

Website trackers Point of sale
software
Track website visitor’s
movement around a site and Computer software
programs that track a
see what attracts interest. customer’s purchases
are available, allowing
Competitions marketers to tailor offers
to their spending habits.
Use competitions to collect
information, from opinions

to demographic data.

Transactions Mobile technology

Ask questions at The use of smartphones
checkout—in the store, enables marketers
online, or on the phone. to compile data, for
example the frequency
of customer visits and the
amount of time they
spend in the store.

Data warehousing

The process of data warehousing involves information from a company’s
internal system, such as invoices and sales logs, as well as data from
outside sources, being filed away in an electronic vault.

How it works The data is often used to assess 50%
beliefs and intuitions about
The data warehouse is a repository the business. For example, of companies
that holds the company’s sales and the marketing manager of a surveyed in 2011
operational history, as well as power tools company might were not sure their
relevant economic and trade presume that 25–35-year-old data warehouses
information from other sources. men are more likely to purchase were future-proof
The data goes through three stages their products than women in
before it is stored in the warehouse, the same age bracket. The
which makes it usable for analytical manager would test this belief
purposes. Once stored, the data by analyzing sales data and
may be accessed by all areas of customer records accessed from
a company—from accounts and the data warehouse.
operations to sales and marketing.

Warehousing process

The data stored is regularly updated. When the business requires information
from the warehouse, it is transformed into an accessible format and analyzed
using software tools.

Tapping data sources OLTP Staging data
Includes
The information a company collects transactions such The ELT process
includes online transaction processing as sales and converts raw data
(OLTP) data, historical data, and data refunds recorded into a usable format.
from external sources. via OLTP

HISTORICAL
DATA

Repository
of past sales
information

EXTERNAL EXTRACT, USABLE
DATA LOAD, FORMAT

Includes TRANSFORM USABLE
government (ELT) FORMAT
statistics on

business

256 257HOW SALES AND MARKETING WORKS
Information management

WHO USES THE DATA WAREHOUSE?

The key departments of a company FINANCE $
can access the data warehouse to find “What was profit
out how they are performing. The margin on product MARKETING
method in which the data is formatted sold in a region?” “How did online ad compare
and stored makes it possible for them to poster ad campaign?”
to seek answers to questions relevant
to them. Typical questions various SALES
departments might ask include: “What are average sales
of product by region?”

HUMAN RESOURCES
“How much have we spent
on contract staff this year?”

Storing data Accessing data

The data is stored in three Using software, the data can be
sections: metadata, summary analyzed and retrieved in three
data, and raw data. ways: via online analytical
processing (OLAP), reporting
METADATA tools, and data mining.
Information
relating to the OLAP
data itself Accesses data to
answer specific
SUMMARY
DATA questions

Business activity REPORTING DATA MINING
information TOOLS Finds detailed
patterns in data
RAW DATA Presents data as
The original tables or graphs for analysis
form of the
information

Customer profiling

Marketers can create detailed portraits of customers using internal
company data on their purchase habits, preferences, and lifestyle, and
cite external data sources to learn about attitudes and social trends.

How it works the marketplace. The information Psychographic view
they look at includes basic data
In order to best understand their about a person, such as gender, age, ❯ Personality Outspoken; likes
audience, marketing departments occupation, and salary, as well as to stand out from the crowd
define their ideal customer by more detailed ideas concerning
developing a customer profile. the person’s typical spending habits, ❯ Attitude Positive outlook and
They build this profile by gathering such as the places where they enjoys the good things in life
information about the kind of like to shop and the amount they
person who usually buys the type tend to spend. ❯ Ethic Works hard and believes
of product they wish to introduce to in contributing to social causes

Segmentation model

By constructing a segmentation model, layered with a number of variables
(different levels of information) about consumers, marketers can gradually build
up a clear picture of their ideal target customer—in this case, for a travel company.

Woman, age 35 to 54, with household Demographic
income of $85,000+ variables

Lives in New York City metropolitan area Geographic
Shares with 125 friends on social media variables

Sociographic
variables

Wants to get in shape while Psychographic
on vacation variables

Takes two or Behavioral
more getaway variables
trips per year

with family

258 259HOW SALES AND MARKETING WORKS
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Behavioral view Sociographic view 75%

❯ Shopping location Prefers ❯ Social media Actively shares of marketers say
to shop in smaller stores interests with connections personalization
could have a
❯ Purchasing habits Buys in ❯ Community Influential significant effect
bulk to save money, responds member who socializes and on customer
to discounts contributes to neighborhood retention

❯ Degree of loyalty Faithful ❯ Groups and clubs Member of
to a brand, but open to bird-watching and hiking groups
better offers

Customer Geographic view
profile
❯ Continent North America
dimensions ❯ City Booming metropolis with

What does the ideal customer look work and social opportunities
like? Where do they live? What do ❯ Climate Varies from below

they spend their money on? freezing in winter to hot and
humid in summer

Demographic view

❯ Age group 35–54 (helps
gauge family priorities and
income)

❯ Status Married (children affect
spending choices)

❯ Occupation and salary
Teacher, $65,000

CUSTOMER PROFILING

Creating a customer profile

By constructing a profile of an existing customer using data from within the
company, marketers have a clearer view of the buying patterns and habits
of an individual. They can then make projections about the long-term
value of that individual as a customer.

WWW WEBSITE DATA
How often do they visit the site?
Which web pages do they look at?

SOCIAL DATA
Which social media networks are they
connected to? Do they share links?

TRANSACTION DATA
How much have they spent, how
often, and on which products?

CRM DATA
What’s their contact history with call
centers? How have they responded
to campaigns?

LOYALTY DATA Customer
How loyal are they to the company? Do profile
they use the company loyalty program?

@ MAIL DATA
What email contact has there been?
What has the response rate to emailed
content been?

$
POINT OF SALE
What observations have sales staff
made from interacting with customer?

260 261HOW SALES AND MARKETING WORKS
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“Once you understand SEGMENTATION
customer behavior, SYSTEMS
everything else falls
into place.” Once marketers have gathered data
and identified their ideal customer
Thomas G. Stemberg profile, they can compare their
customer to a number of commonly
Assessing customer profile used systems of segmenting, or
characterizing, consumers. In the
Good customer Bad customer US, there are many systems, but one
of those most well-known is that of
❯ Returns frequently to ❯ Bombards call center the Nielsen company, which uses
make repeat purchases with complaints more than 60 segments that have
names like “Boomtown singles”
❯ Responds to marketing ❯ Frequently returns products and “Up-and-comers.”
and in-store promotions for full refund
In the UK, customers may be
❯ Shares favorite products on ❯ Never joins loyalty programs compared to the simple system
social media networks or signs up for newsletters of socioeconomic class:

❯ Signs up for newsletters ❯ Spends less money than A Managerial and
and special offers the cost of courting them professional

B Middle management

C1 Clerical and junior
management

C2 Skilled manual workers

D Working class

E Non-working and
low-paid workers

Three ways to use a customer profile NEED TO KNOW

1 Tailor content to suit customer By sending out ❯ Omnichannel customer
personalized messages and experiences, businesses Consumer who shops using
engage customers and build a long-term relationship. multiple channels, including
store visits, mobile apps,
2 Sell more to existing customer Mining customer and websites
profiles to see their spending habits, likes, and interests
enables marketers to make personalized offers. ❯ Loyads Customers who are loyal
to a provider and champion them,
3 Reward loyal customers Identifying good customers bringing in other customers
and offering gifts and incentives tailored to their tastes in the process
increases customer lifetime value.
❯ 360-view Profile that gives
marketer a complete picture of
a customer, making it possible to
predict their needs and behavior

Big data

Business is trying to harness the huge amount of consumer data now
available online. This information can be analyzed and used to create
detailed profiles to target customers more precisely.

How it works documents. The challenge for most organizations is to
sift through big data to find information that has the
Big data is the huge amount of digital information potential to add value to their business. Software tools
transmitted via the internet every day. It is streamed are now available that can analyze the masses of
at high speed and in many different formats, from external data generated on the internet.
database statistics to video, audio, and email

ExInternally and externally mined big data Big data
store
Businesses are now able to access data from sources such as mobile
communications, social media networks, and commercial Big data
transactions, which show the activity of billions of people.
The volume of data is potentially so
ternal data sourceAn ever-expanding amount of data is being vast it cannot easily be moved and
may overwhelm most organizations.
generated by outside organizations, which
will prove increasingly valuable to businesses.

Social media Big data vendor

Data monitors what people are saying about the Provides services, systems, and
organization and its products. tools enabling companies to
store, access, and analyze data.
Audio Vendor offers applications to
suit individual business needs.
Data includes news broadcasts, interviews, call center
recordings, and podcasts.

Photos and video

Data comprises blogs, images, video recordings
from entertainment media, and surveillance.

Public data

Information shared outside
the company, such as press
releases, job descriptions,
and marketing materials.

262 263HOW SALES AND MARKETING WORKS
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38% NEED TO KNOW

of marketers had a ❯ Apache Hadoop Open-source software
centralized database for library for storing and processing big data
customer data by 2014
❯ Terabyte One trillion bytes
❯ Petabyte Unit of digital data equivalent

to 1,024 terabytes
❯ Exabyte Unit of digital data equivalent

to 1,024 petabytes (five exabytes equates
to all words ever spoken by human beings)

Internal INFORMATION OVERLOAD
data source
The volume of data typically generated
Internal data sent to the big data vault where it online every second:
is traced and recorded is drawn from all parts of ❯ Emails 2,314,084 sent
the organization and forms a unified database. ❯ Tweets 7,231 sent
❯ Instagram 1,129 images uploaded
Transactions ❯ Tumblr 1,362 posts
❯ Skype 1,473 calls
❯ Spend per customer ❯ Internet 22,148 GB of traffic
❯ Foot traffic in stores ❯ Google 44,490 searches
❯ Time spent per visit ❯ YouTube 84,841 videos watched
❯ Facebook 30,000 likes; 5 new profiles
Log data
DATA MANAGEMENT
❯ Customer reviews
❯ Customer service Organizations can choose either offline or
❯ Audio files of customer online options to store big data and various
software for access and analysis.
service calls, for example ❯ Big storage hardware Servers; storage

@ Emails and network equipment capable of
supporting many terabytes of data
❯ Internal communications ❯ Software Includes programs for research
❯ Customer contacts and analysis, storage and access, and
❯ Email campaigns graphic visualization of data
❯ Cloud services Third-party providers
that offer storage networks for big data
management and access

Customer relationship
management (CRM)

CRM (customer relationship management) is a computerized system used
for managing and coordinating marketing, sales, and customer-support
data to maintain good customer relations and improve profitability.

How it works of ways: the sales team may use it to find new business
leads and improve relationships with existing customers,
CRM is a software tool in the company’s IT system the marketing team may use it to reward loyalty, and
that records all interactions the business has with customer service may use it to deal with problems.
customers. The information can be used in a number

NEED TO KNOW CRM system Customer

❯ Technology-enabled The system uses reliable Customer data
relationship management processes that allow companies flows into the CRM
(TERM) Use of automated to connect more efficiently system through
processes to manage customer with customers and ultimately their transactions.
relationships offer better service,
resulting in long-term
❯ Enterprise resource planning gains for the company.
(ERP) Precursor to CRM

❯ Cloud-based CRM
Computerized CRM system that
exists in the cloud (online)

AUTOMATION

CRM can use automation as a tool to respond to customers who visit and use a website.

Customer segmentation Email campaign management
Different emails are sent automatically to the relevant groups.
The market can be segmented into groups
relevant to the product the company sells.

@@

intsepreecstiasl age profession Age Location
family size gender Gender Family size
@ @ @
@ @
location

Profession Special interests

264 265HOW SALES AND MARKETING WORKS
Information management

871% Marketing Sales

the average return Target groups for special Convert new leads; find
on investment campaigns; monitor and new prospects; cross-sell
delivered by CRM reward loyalty; generate leads and upsell opportunities;

customize pitches

Customer contact form Price quote

CRM uses the information to group The company sends a price quote
customers according to their in response to the customer’s
buying behavior. interest in their product.

Customer feedback E-commerce transaction

The company asks questions to The customer pays for the product
glean information about the via the internet.
customer’s views.

Support ticket

An automated ticket allows
the customer to track delivery
of the product.

$

$

Operations Customer service Finance

Improve efficiency of Respond to service issues Generate invoices in a
manufacturing, product immediately; manage timely manner; manage
customer cases; gather
delivery, ordering, feedback payment process
and tracking

Compliance

In most countries, companies have to adhere to laws and industry
regulations that govern how they can sell and market their products.
The rules are there to make sure that businesses operate fairly.

How it works terms and conditions, and spam marketing (sending
unsolicited emails). The regulatory body is able to
Governments impose rules on marketers to prevent investigate any company accused of breaking the rules
any unscrupulous, misleading, or unwelcome practices, and impose penalties if it finds the company guilty.
such as false advertising, the failure to disclose all

Marketing regulations

To protect the consumer, regulatory bodies produce guidelines
instructing companies on how they should market their products.

Business areas subject to regulation Example of marketing practice

Comparative claims “Our model is much better than
our competitors’ models!”

Endorsements “I owe my success to their product!”

Special offers “Buy one, get one free!”
Sweepstakes and contests
Telemarketing “Enter the prize drawing for the chance to win
Marketing to children the vacation of a lifetime!”

“Good evening. Would you like to save money
on your energy bills?”

“Step right up and enter the House of Toys…”

Customer data “Please fill in the registration form.”
“Today only—24-hour online sale!”
@ Email marketing

Use of spam “Congratulations! You have been selected…”

Negative-option billing “Please uncheck the box if you do not wish to…”

66% 266 267HOW SALES AND MARKETING WORKS
Information management
of all email traffic
in 2014 was spam NEED TO KNOW

❯ CAN-SPAM Act International legal ruling
that sets out commercial email requirements
and penalties for violation

❯ Phishing Fraudulent sending of emails
while pretending to be a genuine entity, to
gain the recipient’s bank details, for example

Typical regulations to protect consumer

A marketer making a claim that its product is superior to a rival’s must
be able to substantiate it with proof.

A marketer must be able to prove that a person they have used to
endorse a product has used the goods or service they are promoting.

A marketer promoting a product with a special offer must set out the terms and
conditions in writing. In the UK, use of the word “free” is subject to regulation.

All competitions and prize draws must adhere to government
guidelines to ensure that they are fair and impartial.

Telemarketers must promptly disclose key facts of the proposed sale, including
cost and quantity, restrictions and conditions, and refund policy.

Marketers must stick to specific guidelines governing how
they advertise and promote products to children.

Customer information must be stored, managed, and
used in accordance with privacy laws.

It is illegal to use contact lists from external sources. Emails must
disclose their commercial nature to the recipient.

Marketers must refrain from sending bulk unsolicited emails, the most
common form of spam, or other types of unrequested messages.

Any item offered alongside the main product purchased must be presented
as an option to buy, not an item the consumer must take action to refuse.



HOW
OPERATIONS
AND
PRODUCTION
WORK

Manufacturing and production ❯ Management
Product ❯ Control ❯ Supply chain

Manufacturing
and production

Once a firm has decided what goods or services to make, its directors have to
choose the method of production that best suits consumer demand, the product,
and the market, as well as one that will be the most profitable. Companies work in
three general areas of industry, which together form a production chain to provide
consumers with finished goods or services.

Production methods Primary production

Before the Industrial Revolution, products were made The acquisition and processing of raw materials—in this
by craftsmen. Then factories brought people together to case, navy beans, as well as tomatoes for the sauce
work on machines. Typically, this was job production, with
one person making one item. Economist Adam Smith first PRODUCTION IN PRACTICE
introduced the concept of division of labor, which led to Native to South America, navy beans are grown either for the
mass production, with car-maker Henry Ford bringing in immature green pods, eaten fresh as green beans, or for the
the moving assembly line at the start of the 20th century. beans themselves. These are dried and used most commonly
Today, manufacturers can combine the best of all methods, in baked beans, a dish that originally came from Boston, MA.
with large-scale production of personalized products.
Production typically involves three stages—here, from
navy bean to canned beans sold in supermarkets.

CHOOSING THE BEST METHOD

❯ Job production Items are made individually. ❯ Mass customization Mass product is customized by
See pp.272–273. buyer. See pp.278–279.

❯ Batch production A number of items are all made ❯ Continuous production 24/7 line of production, for
together at the same time. See pp.274–275. products with consistent demand. See pp.280–281.

❯ Flow production Suitable for mass-producing identical ❯ Hybrid processes Mixing batch and flow production
items on an assembly line. See pp.276–277. or combining other processes. See pp.282–283.

270 271HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

$2.33 KEY PRODUCTION FACTORS
trillion
To make products, businesses need
the value of China’s annual several resources
manufacturing output in
2011—the largest in the world ❯ Capital Money invested in business, including
money spent on production tools, such as
equipment, machinery, and buildings

❯ Land Natural resources used to create goods
and services—for example, physical land or
extractable resources such as minerals, lumber,
oil, or gas

❯ Labor People employed in a business to
produce the goods and services

❯ Enterprise Entrepreneurs and/or leaders
who bring the factors of production together
to make the whole process happen

Secondary production Tertiary production

The manufacture and assembly of raw Services that support the production and distribution
materials to turn them into a product of the baked beans, such as transportation, advertising,
or service; in this instance, canned beans warehousing, and insurance

The raw beans are mixed with tomato The labeled cans are transported to warehouses and from
sauce, sugar, salt, and secret spices. The there to supermarkets and other outlets to be sold. Several
ingredients are cooked in vast pressure brands vie for market supremacy of this popular convenience
cookers, ensuring consistent texture and food, using advertising, price, and taste differentiation.
a long shelf life, and then sealed in tins.

Job production

In job production, items are made individually. Each item is one job,
which is usually finished before another is started. This method is
typically used for small-scale production or for large one-time projects.

How it works simple and little investment SERVICES
is required. Job production can
Job production is best suited to a also be used for complex projects Job production can also apply to
business that has to meet specific and those involving leading-edge services, such as hairdressing or
customer requirements. Typically, technology, including film processing an order for pickup.
these are unique requests, which production, major constructions Airline flights come under the same
an individual or a team handles such as ships for the navy, umbrella—flight attendants tailor
from start to finish. Made-to- architect-designed buildings, their services to passengers’ dietary
measure suits, or custom-made and structural engineering requirements and special needs for
furniture are examples. The scale projects including bridges items such as wheelchairs.
may be small, and firms often start and tunnels.
with job production because it is

Wedding dress production

A bride-to-be can choose to buy a dress off the rack
(typically made by batch production) or have one specially
designed and made for her, which costs significantly more.

Bride-to-be at the store Dressmaker commissioned Cutting out the dress

The bride cannot find the dress A dressmaker is engaged to The dressmaker makes a pattern
of her dreams and opts to pay for design a wedding dress to the and cuts one dress from the
a custom garment. bride-to-be’s specifications. bride-to-be’s chosen fabric.

272 273HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

JOB PRODUCTION PROS AND CONS $1,211

Pros Cons the average cost of a

❯ Products generally of high ❯ Does not allow for wedding dress in the
quality economies of scale,
so high production costs US, in 2014
❯ Great job satisfaction and
pride in work followed ❯ Labor-intensive $
through from start to finish $
❯ Special materials and $
❯ Producer can satisfy investment in skills may
individual customer needs be required

❯ Can make a profit with ❯ High price may put off
only a few customers customers, especially in
times of recession
❯ For small jobs, word-of-
mouth recommendations ❯ Heavy reliance on just a
reduce marketing costs handful of customers

Sewing the dress Dress fitting Completing the dress

The dressmaker focuses on stitching After any alterations, the dressmaker The price is high, but the dress is exactly
and finishing the one garment. is satisfied that the dress fits the bride- what the bride-to-be wants. Now the
to-be and meets her requirements. dressmaker can start on another dress.

Batch production

When a number of the same items are made together, it is called batch
production. One batch finishes each stage of the production process
before the next batch starts, using the same equipment and steps.

How it works few as four identical items for a local supplier
to thousands for a department store, and
Batch production allows a firm to make a quantity batches can be made as often as required.
of items in one production run. Factory equipment Batch production is common in the food, clothing,
is geared up in terms of scale and special tools footwear, paints, adhesive, and pharmaceutical
that can be changed for each batch. For example, ingredients industries. Each batch must be
equipment is set up to make 200 size 8 dresses in traceable, with clear date stamping, in order
red fabric and then adjusted to produce 400 size 10 to comply with laws and standards.
dresses in blue fabric. Quantities can vary from as

Bread by the batch

Bread is commonly made in batches. A baker might
make 100 white rolls, then 50 large brown loaves.

Mix bulk ingredients Divide dough

Ingredients for the batch of white After machine-mixing, the bulk
rolls are mixed to form a dough. dough is divided into small pans.

Proof dough

The dough is left to
rise (proof) in pans.

Batch 1

Adjust for second batch Divide dough Proof dough

The equipment is recalibrated to After machine-mixing, the bulk The dough is left to
make 50 large brown loaves. Bulk dough is divided into large pans. rise (proof) in pans.
ingredients for the batch of brown
bread are mixed to form a dough.

Batch 2

274 275HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

12 BATCH PRODUCTION PROS AND CONS
million
Pros Cons
loaves of bread were
sold every day in the ❯ Economies of scale: low unit ❯ Repetitive work, so workers
UK, in 2014 costs, as large number is made may be less motivated

❯ Customer offered choice ❯ Costly because may require
of, for example, size, weight, storage of raw materials, work
and flavor in progress, and finished items
(see p.139)
❯ Output and productivity
increases with use of specialty/ ❯ Requires detailed planning
dedicated machinery and scheduling

Bag up to complete

All the rolls finish the production
process together.

Bake rolls De-pan and cool rolls

The whole batch is The rolls are removed from
baked at the same their pans.
time at the same
temperature.

Bake loaves Slice and bag
loaves
Baking time is longer
than for Batch 1, as The loaves
the units are larger. are sliced and
packed for sale.

De-pan and cool bread

The large brown loaves are removed
from their pans.

Flow production

The purpose of flow (mass) production is to produce a large number
of identical, standardized items. This usually happens on a moving
line, which can be interrupted when the product is changed.

How it works example where elements of the car are put together
along a line; robot arms may install wheels and
Flow production typically involves large factories workers may perform specialized jobs. Significant
equipped with conveyor belts and expensive output is possible with even a small number of
machinery, the assembly of individual components, workers. Newspaper printers, oil refineries, and
which may be bought in from other companies, and chemical plants also use flow production.
the automation of tasks. Car manufacturing is an

The production line

In flow production, the item being made, such as a car, moves on a conveyor belt through different
stages until completion. Components to build the car may have been outsourced or produced in
another of the company’s factories. They are all ready to be used along the line.

Chassis assembly Wheel assembly Engine assembly

PARTS ASSEMBLY

Electrical Main body assembly Windshield
assembly assembly

CAR ASSEMBLY

276 277HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

FLOW PRODUCTION PROS AND CONS 60
million
Pros Cons
cars are produced
❯ Economies of scale: can produce ❯ Expensive machinery requires globally each year
large number of goods cheaply significant investment

❯ Unskilled labor keeps costs low ❯ Repetitive work means workers may
❯ Materials bought in large quantities, be less motivated

so low cost ❯ Reliant on equipment: if line breaks,
production is halted

Gear box assembly Radiator assembly Seat assembly

Door assembly Finishing Inspection Ready for
customer

When customer
demand is high,
car companies
may run their
production lines
continuously.

Mass customization

Sophisticated technology and manufacturing developments allow mass
products to be personalized. The low unit costs of mass production
combine with the marketing opportunities of custom-made.

How it works computers already allow consumers FOOD MIXES
to customize their purchases. The
Mass customization offers new price is generally higher than for The generation raised on social
opportunities for the manufacturing standardized goods. media expects to personalize every
and service industries. Social aspect of their lives, and food and
media, online technology, 3-D Revolutionary new technologies drink is set to be a growth area
modeling tools, e-commerce are expected to further extend for mass customization. Websites
software, and flexible production customization, allowing individuals allow consumers to make their own
systems and processes are to, for example, scan their body cereal mixes, which is especially
allowing customers to configure contours and use augmented reality useful for those with allergies, and
products to match their own tastes to design and order unique clothing. to create their own blends of tea
and needs. Industries such as and coffee.
footwear (particularly athletic
shoes), clothing, cars, jewelry, and

Customers design own products

Mass customization has enormous potential to change consumerism. For
example, consumers can buy shoes designed to their own specification
via the internet. This is a high-status commodity among certain groups.

Lace color Laces
Shoe color
Name Tools

The customer decides Sends order to factory

On the company’s website, a drop-down menu, with The firm holds no finished stock
options including style, shape, size, color, and laces, but manufactures to order from
allows consumers to design their own pair of shoes. a range of parts, getting paid by
the customer before production.

278 279HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

$10 FOUR TYPES OF MASS CUSTOMIZATION
million
In his book Mass Customization: The New Frontier in Business Competition,
the total value of B. Joseph Pine II outlines four distinct types:
customized sweets
sold by Mars by ❯ Collaborative customization ❯ Transparent customization
2007, including Work with individual customer to Provide unique products to
coloured M&M’s develop specific product to suit individuals without overtly
their needs. Technology firm Dell, stating items are customized:
for example, assembles computers the Ritz-Carlton hotel group
to customer’s specification. keeps a database of preferences
for pillows and newspapers to
❯ Adaptive customization personalize a guest’s stay.
Produce standardized products
that are customizable by end-user. ❯ Cosmetic customization Make
For instance, US company Lutron a standardized product but market
produces a lighting system that it differently: Hertz distinguishes
lets customers choose own setting its standard rental car from its
from programmed settings. #1 Club Gold program.

Shoes shipped to customer

The customer receives a differentiated
product and has the psychological benefit
of personal design—at a price.

PCatSutieszhrenio7e.n5de,ldnaacserorsloew fit

Continuous production

During continuous production, a product is made 24 hours a day,
seven days a week. The production line runs continuously to cope
with demand, and staff work around the clock in shifts.

How it works electronic components, and oil products. As with mass
production, processes are automated, staffing levels
With flow or mass production, the line is stopped to are kept to a minimum, and quality control is essential.
change products or models. Continuous production
uses the same concept, but it runs throughout the year There is high competition in industries using
so output is nonstop. This method is used for identical continuous production. Margins may be low, but
commodities with high, consistent demand, including demand is often relatively stable, encouraging
paper, cardboard, packaging, laundry detergent, investment in capital equipment.

The paper trail

Paper is used throughout the world, and factories operate 365 days a year to
satisfy constant demand. Lumber is the raw material for papermaking. Once the
lumber has been debarked, chipped, and pulped, the fibers are washed and dyed.
At the end of its life cycle, some paper is recycled.

Wood Papermaking

Lumber is a renewable In this continuous process,
resource and logs are automated machinery runs
stockpiled. Trucks make 24 hours a day, 365 days a year.
constant deliveries to
processors for pulping.

Paper recycling HEADBOX
Fiber and water are fed
Recycled paper is onto a moving wire mesh.
an important resource
for the paper industry.

WIRE SECTION
Some of the water is
sucked away to leave wet
fibers that form paper.

280 281HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

4 billion TYPICAL USES

trees are cut down every Continuous production is used for undifferentiated
year to make paper commodities required in large and constant amounts.

ENERGY : ELECTRICITY A OIL REFINER IES AND CHEMICAL PLANTS
ND GAS

PA PER PRODUCTION GL ASS PRODUCTION

DRYING
The paper is dried off.

PRESS SECTION COATING AND FINISHING
More water is CALENDERING AND SUPPLY
squeezed out of The paper is coated, The finished paper is
the wet sheets. compressed, and constantly supplied
smoothed. to printers, packers,
and newspapers.

Hybrid processes

Manufacturing firms may adapt existing processes or combine two
production methods for optimal performance, particularly if they make
a wide range of products.

How it works capsule, and liquid form, and NEED TO KNOW
in varying doses; each batch
There are many examples of hybrid flows through a series of steps, ❯ Increments Small steps of
processes. One is linked batch flow depending on composition gradual improvement over a period
production, where only two or three and form, from bulk processing of time, rather than breakthrough
pieces of equipment are required to packaging. Another example or transformational change
and a batch flows from one process is cell manufacturing, which
to another. This is common in the combines job production with ❯ Hybridization Replacing several
chemicals and pharmaceuticals flow (mass) production. separate processes with one single
industries. For instance, a company hybrid process
may make headache medication
and a hay fever remedy in tablet,

Combining Flow production

methods One process is handled by one or more workers and that job
is completed before the product or part moves on to the next
On the classic assembly workstation. Worker 1 uses only one set of tools for the process,
line, each worker is skilled before the product moves on to Worker 2, and so on down the line.
at producing one type (See pp.276–277.)
or part of an item. At the
other end of the scale, INPUT
one person completes all
stages, creating the finished WORKER 1 WORKER 2
product from beginning to
end. Cell manufacturing PRODUCTION LINE OUTPUT
combines flow production
with job production to
create autonomous units.
A number of workers are
dedicated to production,
or part-production, of a
set of goods.

WORKER 3 WORKER 4

282 283HOW OPERATIONS AND PRODUCTION WORK
Manufacturing and production

HYBRID PROCESSES FOR INNOVATION

By combining manufacturing dough bread
processes, companies can create potatoes
products with new and original lighter fries
qualities. For instance, a food
company that makes bread french fries
and french fries may speed up
production of the fries by baking
them in the bread oven first. This
has the unintended but beneficial
consequence of making the fries
healthier. A new product is created,
which may now be marketed as
a new proposition to a different
set of consumers.

Job production Cell manufacturing

One worker creates Combining the best of flow and job production, here a group of products
a one-of-a-kind product, or parts is produced in separate small units (cells) made up of a number of
such as a custom kitchen, workers in the factory. Workers are trained to produce all the items in the set.
from start to finish. This Dissimilar items can be produced without slowing the production line. The
way of working can be idea is to improve performance by giving each cell a degree of autonomy.
more rewarding for the
worker, who uses a range INPUT
of skills, but it tends to be
costly for the customer.
See pp.272–273.

CELL 1 CELL 2

WORKER

PRODUCTION LINE OUTPUT

CELL 3 CELL 4

Management

Every manager in a business, particularly in manufacturing, has to
ensure that all resources—from materials to equipment and staff—
are used efficiently, while keeping the customer continually in
mind. Managers make key decisions to lay down procedures
and set standards and then work continuously to improve
processes to ensure that the company remains profitable.

Which approach?

How people and processes are organized in making and delivering the product Agile
to the customer is critical if a company is to survive fierce competition and rapidly production
shifting consumer demands in a global market. In making decisions about how
a business can meet its goals, managers may combine a number of approaches How can we be more
as many are interlinked and achieve similar outcomes. responsive to shifts in
customer demand?
See pp.296–297.

MANAGER OR LEADER?

Management and leadership are not the same, but are Time-based
closely linked: management

❯ Managers plan, organize, and coordinate; leaders How can we use
also galvanize and motivate. time effectively?
See pp.294–295.
❯ Managers organize workers to maximize efficiency;
leaders also nurture skills and develop talent. No.1

❯ Managers focus on the bottom line; leaders also country for
look to the horizon. innovation in
2014: South Korea
❯ Managers tell people what to do; leaders also
ask questions.

❯ Managers make sure workers are doing everything
that needs to be done; leaders also inspire workers
to want to do more than needs to be done.

The following classic distinction has been attributed to
two different business leaders and writers, Peter Drucker
and Warren Bennis: management is doing things right;
leadership is doing the right things.

284 285HOW OPERATIONS AND PRODUCTION WORK
Management

$$

Kaizen Economies and
diseconomies of scale
How can we drive
continuous What scale of operation is best
improvements? for us? See pp.286–287.
See pp.298–299.

INNOVATE Lean
production
INVOLVE FOCUS
EMPLOYEES ON VALUE $ How do we
minimize
resources to
reduce costs?
See pp.288–289.

STRATEGIC MINIMIZE
ALLIANCES WITH WASTE

SUPPLIERS

UNINTERRUPTED CUSTOMERS Just-in-time
WORKFLOW AT THE HEART
How can we meet customer
OF WHAT demand and minimize stock?
WE DO See pp.290–291.

Total quality
management

How do we improve customer
satisfaction? See pp.292–293.

Economies and
diseconomies of scale

Economies of scale are one of the advantages of large-scale production
and result in a lower unit cost of each item produced. However, costs can
also go up as the operation grows, resulting in diseconomies of scale.

How it works Supermarkets, for example, buy food in bulk at low
unit costs, which they pass on to consumers. However,
Economies of scale is a simple concept: the more items diseconomies of scale may occur when the operation
produced or handled, the cheaper the average (unit) grows because of high administration costs, wastage
cost, as efficiencies and fixed costs are shared across all from lack of control, or lack of employee productivity.
items. This gives a business a competitive advantage.

Economies of scale

While it may be inefficient for a small dairy to supply milk to a supermarket,
it is cost-effective for a large dairy operation producing thousands of bottles.
If a delivery is too large, though, wastage can creep in due to associated costs.

SUPERMARKET

AVERAGE COST AND REVENUE DELIVERY 1 VEHICLE
OF 100
BOTTLES

Average cost high

Few economies of scale DELIVERY
OF 10,000
$ BOTTLES

Average cost low

Economies

286 287HOW OPERATIONS AND PRODUCTION WORK
Management

NETWORK ECONOMY 150
million
Online networks, such as eBay and Facebook,
rarely stray into diseconomies of scale. They can the number of eBay
deliver economies of scale even at an international users worldwide in 2014
level: the cost of adding one more user to a
network is almost zero. However, the resulting
benefits may be huge, because each new user
in the network can interact or trade with other
members of the network.

2+ VEHICLES = MORE SUPERMARKET
DRIVERS AND FUEL AND
1 VEHICLE (LARGER,
BUT ONLY ONE POTENTIAL WASTAGE

DRIVER AND SAME DELIVERY
FUEL COSTS) OF MORE

THAN
10,000
BOTTLES

Average cost goes up

SUPERMARKET

of scale Diseconomies of scale

OUTPUT

Lean production

The goal of lean production is to reduce the resources used to supply
goods and services to consumers. By cutting down human effort,
materials, space, capital, and time, lean production cuts costs.

How it works Optimizing the flow of products NEED TO KNOW
and services through value
The focus in lean production is on streams—sequences of activity ❯ Kanban cards Toyota’s demand-
efficiency to maximize value for that flow horizontally across driven scheduling triggers
the customer, but without affecting technologies, assets, and functions
quality. Lean seeks to eliminate all to customers—allows the business ❯ Value-stream mapping
activities that do not add value to to respond more quickly to The process of analyzing how the
the production process, including consumer demand. Efficiency also product gets from start to finish
holding inventory (stock), repairing makes it simpler and more accurate now and the design of an
faults, and unnecessary movement to manage information. improved flow for the future
of people and products around a
manufacturing plant.

Case study: Overproduction Waste Waiting Waste

how Toyota Items produced Unproductive
surplus to time spent waiting
eliminates customer for material,
demand information,
waste equipment, tools
Lean solution
Lean production is Lean solution
about getting rid of Manufacture based upon a pull system,
waste, sometimes producing products as customers All resources provided
called non-value- order them on a just-in-time ( JIT)
added activities. basis—not too early,
Car manufacturer Waste not too late (see
Toyota has identified pp.290–291)
eight areas of waste Extra, unwanted
and a lean approach stock held in Waste
to counter these. inventory
Consumes materials
Excess inventory Defects and uses up labor;
results in customer
complaints

Lean solution Lean solution

Kanban cards used to Total quality
indicate material order management (see
points: how much, from pp.292–293) used to
where, and to where improve all areas

288 289HOW OPERATIONS AND PRODUCTION WORK
Management

BENEFITBENEFITS OF LEAN PRODUCTION 10
million
According to a US National Institute of Standards and Technology survey,
40 firms implementing lean production reported these benefits: the number of cars
Toyota expected
Amount of space required reduced by 75% to sell in 2014
Quality improved by 80%

Work-in-process inventory reduced by 80%
Productivity increased by 50%
Lead time (taking product from start to finish) reduced by 90%
PERCENTAGE

Transportation in stages Waste A B C Non-value-added processing Waste
B
Superfluous Unprofitable stages
stages in the in the production
transportation or reworking of
process a product

Lean solution A Lean solution

Material shipped Map the value stream to
directly from the identify non-value-added
vendor to the steps in the process; get it
assembly line right the first time

Excess motion Waste Underused people Waste

Poor workflow, Underutilization of
poor layout, employees’ mental,
and inconsistent creative, and physical skills
working methods and abilities

Lean solution Lean solution Work

Workplace Organization, cells replace assembly line;
a systematic method better use of labor and
for standardizing the employee involvement
workplace and communication

Just-in-time

The system of production in which an actual order is the trigger for
an item to be manufactured is called just-in-time. It enables a firm to
produce only the items required, in the right amount, at the right time.

How it works of frequent deliveries and loss of
purchasing economies of scale
Also called demand-pull production, (discounts for bulk buying). The
just-in-time means that stock levels system dates back to 1953, the
of raw materials, components, work year Toyota brought in just-in-time
in progress, and finished goods are manufacturing. The phrase is
kept as low as possible, reducing sometimes used in a more general
costs. The system requires detailed sense today to mean eliminating
planning, scheduling, and flow waste of resources.
of resources throughout the
production process, now assisted 5 NEW STOCK IS DELIVERED TO
by sophisticated production- STORE TO REFILL SHELVES
scheduling software. Supplies
have to be delivered directly to
the production line when they
are needed, requiring strong
relationships and interconnected
systems with suppliers. The
benefits of reduced inventory
are balanced against the cost

JUST-IN-TIME 4 SYSTEM
PROS AND CONS TRIGGERS
DELIVERY FROM
Pros SUPPLIER WHEN
MINIMUM STOCK
❯ Lower stock so less storage space LEVEL REACHED
and less working capital needed

❯ Demand-pull avoids obsolete,
out-of-date stock

❯ Staff spend less time checking
and moving items

Cons

❯ No room for error—for instance,
if there are any faults in the
stock delivered, the whole
day’s production is halted

❯ Operation is reliant on suppliers
❯ No cushion for sudden upsurge

in demand

290 291HOW OPERATIONS AND PRODUCTION WORK
Management

1 CUSTOMER $62
SELECTS billion
ITEM FROM
SHELF the value of
Dell computers
Just-in-time in retail sold in 2012

To reduce stock levels, many supermarkets
now use just-in-time deliveries, relying on
computer data systems. In manufacturing,
systems are often based on Kanban cards—
dockets for withdrawing and ordering items at
each workstation of the production process.

2 CASHIER SCANS
BARCODE

3 COMPUTER SYSTEM CASE STUDY
SIGNALS WAREHOUSE
Dell’s just-in-time computers

Computer produced when customer orders it:
❯ Customer’s individual specification is sent

straight to factory floor.
❯ Just in time manufacturing sees deliveries

of supplier parts arriving at one side of the
factory and unloaded directly into bins to
build customer order.
❯ Inventory and costs are reduced.

Total quality
management

Success though customer satisfaction is the ethos of total quality
management (TQM). Everything a company does is relevant, and the
focus is on managing and improving processes rather than outcomes.

How it works satisfaction. The organization is WHAT TQM MEANS
viewed as a series of horizontal
Companies use TQM to create a processes that take inputs from ❯ Total Involves everyone and all
customer-focused organization suppliers through to the outputs activities in the company
that involves all employees in that are delivered to the customer.
continuous improvement. It is a Recording and measuring ❯ Quality Conformity to meeting
strategic and systematic approach performance data is critical, as customer requirements
that puts quality at the heart of the is effective communication to
organization’s activities and culture. maintain momentum. ❯ Management Quality can and
Customers determine the level of must be managed
quality, measured through their

Case study: The Walt The Walt Disney Focus on the customer
Disney Company Company
Disney incorporated the
Manufacturing companies, in which Disney’s goal is to maximize TQM concept of quality into
the focus is on meeting or exceeding long-term shareholder value, its approach to customer
customer expectations by making and part of this involves service. Its visitors are seen
products within certain specifications, delivering a magical customer as guests and treated as VIPs
are often used as TQM examples. TQM experience at its theme parks. and individuals.
can also be applied in service industries,
of which Disney is a very good example. Involve everyone Perfect processes
in quality
“TQM is a Walt Disney viewed the theme
philosophy for Founder Walt Disney firmly parks as factories producing
managing an believed in quality and saw it delight. He built quality by
organization to as everyone’s job, something designing processes and
meet stakeholder that could not be delegated. repeating them.
needs without
compromising
ethical values.”

Chartered Quality Institute

292 293HOW OPERATIONS AND PRODUCTION WORK
Management

12,000 NEED TO KNOW

Disneyland “cast members” are ❯ American customer
satisfaction index (ACSI)
employed to make guests happy Cross-industry benchmarks for
customer satisfaction in the US;
Employees Exceptional service NCSI is the UK equivalent

Disney calls its employees Cast members (employees) ❯ Net Promoter Score (NPS®)
“cast members.” They are are focused on delighting Metric for company performance
trained in every aspect of the customer—their sole job from the perspective of customers,
delivery, including posture, is to make visitors happy. who are divided into promoters,
gestures, facial expressions, passives, and detractors
and tone of voice.

Suppliers Continuous
improvement
Disney collaborates with
suppliers—for example, it has Walt Disney saw the theme
partnerships with McDonald’s parks as an incomplete
and Coca-Cola—to ensure product; today, improvements
consistent quality. come from the bottom up.

“When does the Three Shared purpose Integrated systems
O’Clock Parade start?”
Walt Disney started by Technology supports the
Cast members are trained to defining a company culture experience: for example, the
answer this common question based entirely on creating volume of ambient music is
by responding with the time a genuine shared purpose the same in all theme parks,
the parade will be passing a that people would be proud delivered through thousands
particular point in the park. to support. of perfectly placed speakers.

Time-based
management

The general approach that recognizes the importance and value
of time and seeks to reduce the level of unproductive time in an
organization is called time-based management.

How it works its people have to be multi-skilled and able to move
swiftly between different tasks; its machinery has to
The fast pace of competition means a business that be flexible so that production runs can be changed at
can manage time efficiently will enjoy a significant short notice; and there has to be a culture of mutual
competitive advantage. This applies to new product trust between workers and managers. Time-based
development, faster response times to meet changing management is a key aspect of lean production.
market and customer needs, and reduced waste. For a
business to operate a time-based management system,

Case study: Before INVENTORY
$200 MILLION
managing time in PRODUCTION CYCLE
$$ 15 DAYS
Ford Electronics
INVENTORY Change created new
Between 1988 and 1994, Ford $100 MILLION focus on measuring
Motor Company’s electronics and improving speed
division implemented a number $$ of operation.
of change programs. One that
used time-based management PRODUCTION CYCLE
had a sustained and dramatic 1 DAY
impact on the company’s
performance. A senior leader
led the program with visits to
the factory, where the focus was
on the length of the production
cycle and adding value at every
stage. The factory worked with
suppliers to improve shipment,
reliability, and quality of raw
materials used.

After

294 295HOW OPERATIONS AND PRODUCTION WORK
Management

70% PART OF PROJECT MANAGEMENT

of companies use Time-based management is a critical ❯ Methodologies such as Agile
formal project- part of project management. Timing help project managers working
management aids include: in software development
methodologies respond to the unpredictable;
❯ Tools such as Gantt charts show they are often implemented via
the project schedule as a bar chart, the Scrum framework, in which
making it easy to plot and monitor one person takes charge of constant
daily progress and targets. reprioritizing. Based on the premise
that software cannot be built up like
❯ Project management systems a product on an assembly line, as it
PRINCE2 (PRojects IN Controlled would be out of date before it was
Environments) and similar methods released, every area of development
help to structure projects step by is constantly reappraised.
step in logical, organized ways.

Measuring by the unit $

Measuring the units produced per person
had created an environment where
supervisors focused on daily production
requirements and keeping staff busy.

213 NEW FACTORY
EVERY YEAR
LESS COMPETITIVE
Regularly finding extra
floor space was a necessity

due to high inventory.

POOR STAFF PROFIT LESS THAN
MOTIVATION $100 MILLION

Measuring by cycle $$
$$
Simply measuring performance
in a different way—over a shorter PROFIT
production cycle—allowed people $400 MILLION
to see new opportunities.

213 NEW FACTORY
EVERY 2–3 YEARS
STAFF MOTIVATED MORE
Reduction in inventory
meant floor space was no
longer required so fewer
new facilities were needed.

COMPETITIVE

Agile production

Speed and agility are the key competitive advantages of agile
production: the focus is on rapid response to the customer, enabling
the business to take advantage of short windows of opportunity.

How it works Rapid response

The goal of agile production is to stay ahead of the Company setup allows it to
competition. Often incorporating concepts of lean respond quickly and effectively
production (see pp.288–289), agile has an extra to customer and market demands
dimension: meeting customer demand rapidly and
effectively. It relies on flexible and collaborative workers, Agile manufacturing
who can deliver swiftly and effectively. The company
has to be able to change or increase production quickly. The organization has to create a position
Design of products might incorporate modular concepts, from which it can alter course as nimbly and
allowing for customization, and strong relationships swiftly as a cheetah. It needs to be able to
with suppliers are essential. retool facilities quickly, modify agreements
with suppliers, and continually introduce
C ustomer new ideas and improvements.

Customer
demand is
trigger to start
production

Product Integrated
reaches technology
consumer
Effective information
systems, often linked
to suppliers

Continuous innovation

Constant search for new and better
ways to deliver for customer

296 297HOW OPERATIONS AND PRODUCTION WORK
Management

Modular LOCAL EDGE
products
Agile production is typically adopted
Independently by companies in extremely competitive
created parts used environments with high labor costs,
in different/ such as North America, where local
customized manufacturing can provide a
products competitive advantage:
❯ Proximity to customers allows
Knowledge
culture feedback and response.
❯ Small variations in performance and
Capturing
experience, learning delivery can make a huge difference
from mistakes in customer satisfaction, company
reputation, and financial results.
3 months ❯ Unprecedented levels of speed and
personalization cannot be matched
the time it took Wikispeed by offshore competitors.
to develop a revolutionary
new car in 2012 Strategic partnerships

Transportation Supplier collaboration rather
system than contract negotiation

Systems, facilities,
infrastructure to
speed product to
customer

Flexible
workforce

Self-organizing,
adaptable teams

Kaizen

Started in Japan, kaizen is a system of continuous improvement that
involves all employees. From senior managers to people on the shop
floor, everyone is encouraged to suggest improvements day to day.

How it works standards and then looking for ways to continually
improve those standards. It is supported by
The kaizen philosophy is “to do it better, make it better, a framework of training, communication,
improve it even if it isn’t broken, because if we don’t, and supervision, and results in improved
we can’t compete with those who do.” Kaizen is rarely efficiency, productivity, quality, lead
about ideas for major change but has more to do with time, and customer loyalty.
ongoing, systematic, incremental improvement. A
relentless attempt to eliminate unnecessary activities,
delay, or waste (muda), Kaizen starts with setting high

Creating good change Innov ate

Kaizen events are implemented through a cycle of activity, Quality
known as plan, do, check, act. Central to kaizen are quality,
ongoing effort, involvement of every employee as part of
their daily work, willingness to change, and communication.

BETTER 70 Innovate—find
AND BETTER and implement

Kaizen was created in Japan better ways to
after World War II. It comes meet requirements and
from the Japanese words kai,
which means “change” or “to increase productivity.
correct,” and zen, which means
“good.” Companies such as Effort
Toyota and Canon have seen
significant improvements by suggestions per Gauge
involving their employees in employee were
recommendations for change. implemented at
Toyota in 1983
KAI ZEN

Gauge measurements
against required standards.

CHANGE GOOD