A contingency theory approach to the deployment of lean principles: The case of advanced research and complex product development environments

The introduction of lean principles is a common approach for organizations seeking to improve quality, lower cost, and shorten time to market. Many companies have applied lean to manufacturing, but a smaller number have brought it upstream to product development. This research focuses on how organizations can begin the transformation to lean product development through three essays.;The first study is a comparative case analysis comparing approaches based on "rational planning" and "disciplined problem solving" to identify their relative advantages and disadvantages and organizational characteristics that enable successful deployment. The comparison shows that in the case of non-routine processes like product development the disciplined problem solving approach is more effective, while the rational planning approach can be effective for highly routine aspects of the job.;The second study is an in-depth case study of how value stream mapping and obeya, two common lean product development tools, if used properly, can help cross-functional development teams achieve coordination and integration as well as team member engagement. This facilitates the learning of lean as a socio-technical system with a culture of problem solving and people development through the effective development of a product.;The third study looks at how standardization can be used to establish an enabling bureaucracy with structures and standards effectively supporting people's work. A common misunderstanding is that standardization kills creativity. It can be used to create predictability while maintaining flexibility and enabling innovation. Coercive bureaucracies result when formalization is used to control employees or when there is a misalignment between task requirements and the standards and/or organizational design. Having the people doing the work develop, maintain, continuously improve, and adapt the standards is an effective way to create an enabling bureaucracy.;The insights from this study help to understand the challenges of lean deployment and characteristics that enable success in lean transformations. This can serve as an example to aid in the transformation to lean systems in other complex environments.