Escolar Documentos
Profissional Documentos
Cultura Documentos
Introduction
In the last decade a growing number of authors have pointed out the crucial role
played by manufacturing in supporting the achievement of the overall business
strategy of a company[1-4]. This role has been often summarized in the concept
of manufacturing competitive priorities, that represent the deployment of the
business strategic objectives at the level of manufacturing. Many authors have
dealt with this concept, classifying competitive priorities into several
categories, such as quality, timeliness, flexibility and dependability[1,3,5].
Competitive priorities have to be explicitly considered in the design of a
manufacturing performance measurement system, aimed at monitoring the
correct implementation of the manufacturing strategy at all levels of the
manufacturing organizational structure. Hence, a manufacturing performance
measurement system should be able to assess the overall level of support that
each department provides to the achievement of the competitive priorities.
This result cannot be obtained through traditional approaches to
manufacturing performance measurement, based on costs schemes and
operating efficiency measures, since they do not fit the changing role of
manufacturing. For this reason many consultants, academics and professionals
have suggested integrating financial measures with non-financial indices[6-11].
The use of non-financial measures in performance measurement implies two
major problems:
(1) the selection of a proper set of measures capable of assessing and
controlling all critical factors, on the responsibility of a given manu-
facturing department, that act on the competitive priorities;
(2) the integration of those several measures, expressed in heterogeneous
units, into a single evaluation of the overall performance of a manufac-
turing department.
International Journal of Operations
& Production Management, Vol. 16
No. 8 1996, pp. 104-119. © MCB Financial support from the progetto strategico “CNR Gestione Strategica dell’ Innovazione” is
University Press, 0144-3577 gratefully acknowledged.
While the first problem has been widely discussed in the literature[12-15], little An AHP
attention has been paid so far to the second problem, in spite of its important framework
implications for manufacturing managers and management accountants
(concerning, for instance, the design of effective evaluation and rewarding
systems). This shortage of the literature on manufacturing performance
measurement is especially critical in many current competitive environments,
where the manufacturing strategy is based on several competitive priorities 105
and, for each priority, on many performance objectives.
The construct of production competence, introduced by some authors[16,17]
to calculate the overall support provided by manufacturing to the business
strategy, can be considered an attempt to deal with the integration of
manufacturing performances and to address trade-offs among them. In fact this
construct is a theoretical framework that can be useful for a researcher to
investigate the linkages between manufacturing effectiveness and the overall
performance of a company[18,19], but it does not represent a pragmatic tool
capable of supporting manufacturing managers and management accountants
in structuring and integrating the several performance measures relevant to a
given manufacturing department.
The purpose of this article is to contribute to address this problem, by
showing the application of the analytic hierarchy process (AHP) to measuring
and comparing the overall performance of different manufacturing
departments on the basis of multi-attribute financial and non-financial
performance criteria.
This article does not report the detailed analytical description of the AHP,
widely discussed in literature, but focuses on the assumptions, limitations,
practical problems and managerial implications related to the application of the
AHP to measuring and comparing manufacturing performance.
Overall objective
Criteria
Sub-criteria
Figure 1.
The hierarchical Decision
structure of a decision alternatives
problem
Environmental
Quality Flexibility compatibility
Conformance Inspection Rationalization Product Volume Technology Solid Energy Factory green
rate costs degree flexibility flexibility flexibility waste consumption image
Figure 2.
The performance
A B C D hierarchy
At the second level there are operating measures that play an important role in
contributing to each competitive priority:
• conformance rate (percentage of products that meet the customer
requirements), inspection costs (expressed as a percentage of the
overall production costs) and a qualitative measure of the
rationalization degree of the operating procedures are the quality-
related measures;
• flexibility is measured by product flexibility and technology flexibility,
which are qualitative measures of the possibility to introduce at low
cost respectively new products and new operations, and by volume
flexibility, a qualitative index of the capability to make rapid volume
changes[32];
• environmental compatibility indexes are: solid waste (measured by the
ratio of tons of waste to production volume), energy consumption
(measured in fuel oil equivalent tons per product) and a qualitative
measure of the green image of the factory in relation to local people and
institutions[33].
IJOPM Finally, at the third level of the hierarchy, there are the four factories, referred to
16,8 as A, B, C and D, that must be assessed and compared.
The performance hierarchy described above highlights a typical problem of
many manufacturing performance measurement systems, that is the
heterogeneity of the measurement units of the indexes. In fact there are:
• financial measures: inspection costs;
108
• non-financial physical measures: conformance rate, solid waste, energy
consumption;
• non-financial qualitative measures (intangible): rationalization degree,
product, technology and volume flexibility, green image.
The heterogeneity of the measurement units makes it difficult to assess and compare
the overall level of support provided by the factories to manufacturing strategy.
The several software packages that implement the AHP present a friendly
interface that supports effectively managers in developing the performance
hierarchy. Such a step can play an important role in the assessment process,
since it allows a complex problem to be better understood by structuring it in an
organized form.
Equally preferred 1
Moderately preferred 3
Strongly preferred 5
Very strongly preferred 7
Table I.
Extremely preferred 9
A typical example of
measurement scale for Note:
the AHP Intermediate levels can be used to provide additional levels of discrimination
It is important to point out that a 1-9 preference scale can be used only if one An AHP
factor is up to nine times as important as another factor. If this does not occur, framework
managers have to choose a different preference scale, consistent with the
specific assessment problem.
The pairwise comparison data are organized in the form of a matrix and are
summarized on the basis of Saaty’s eigenvector procedure, in the absolute
priority weights that will be used to calculate the overall score of each factory. 109
The pairwise comparison data are translated into the absolute values by
solving the following matrix equation:
A * AW = k * AW
where:
A = the pairwise comparisons matrix;
AW = the vector of the absolute values;
k = the highest of the eigenvalues of the matrix A.
Tables II-V report the paired comparison data and the absolute weights of the
manufacturing competitive priorities and of the performance measures of the
example problem.
It should be noted that the quality of the output of the AHP, i.e. the calcula-
tion of the overall support of the factories to the manufacturing strategy, is
strictly related to the consistency of the pairwise comparison judgements given
Table V.
The paired comparison Solid Energy Green Absolute
data and the absolute waste conservation image weight
weights of
environmental Solid waste 1 5 3 0.648
compatibility-related Energy conservation 1/5 1 1/2 0.122
measures Green image 1/3 2 1 0.230
In order to consider in the AHP the judgements of several people, two different
approaches can be followed:
(1) to resort to a “facilitator”, i.e. a person who has the task to arrive at a
consensus on the judgements of the members;
(2) to aggregate the individual paired judgements on the basis of a
mathematical operator like, for instance, the geometric mean (see, for
instance, [36]).
Absolute
Factory A B C D rating
Table VI.
A 1 4 6 1/3 0.287 The pairwise
comparison judgements
B 1/4 1 2 1/5 0.069
and the absolute ratings
C 1/6 1/2 1 1/8 0.079 of the factories’
D 3 5 8 1 0.565 rationalization degree
Absolute
Factory A B C D rating
Table VII.
A 1 1/3 1/5 1 0.099 The pairwise comparison
judgements and the
B 3 1 1/2 3 0.284
absolute ratings of the
C 5 2 1 5 0.518 factories’ product
D 1 1/3 1/5 1 0.099 flexibility
Absolute
Factory A B C D rating
Table VIII.
A 1 1/2 1/4 2 0.169 The pairwise comparison
B 2 1 1/2 1 0.445 judgements and the
C 4 2 1 2 0.445 absolute ratings of the
factories’ technology
D 1/2 1 1/2 1 0.163 flexibility
Absolute
Factory A B C D rating
Table IX.
A 1 1/4 2 1/3 0.118 The pairwise comparison
B 4 1 8 1 0.441 judgements and the
absolute ratings of the
C 1/2 1/8 1 1/6 0.059 factories’ volume
D 3 1 6 1 0.382 flexibility
IJOPM cannot be followed and, thus, we have to resort to the comparison procedure for
16,8 quantitative performance measures. This situation is frequent in many
manufacturing environments because of, for instance, the saturation effect or
the critical hurdle effect.
In the first case, it is not true that improving a given performance measure
implies a proportional increase of the level of support to manufacturing
112 strategy, since performance above a certain level is not particularly appreciated
by customers.
Absolute
Factory A B C D rating
A 82 0.245
Table XI. B 90 0.269
Translating the
conformance rates into C 78 0.233
absolute ratings D 85 0.253
Level of support to
competitive priority
Figure 3.
An example of
saturation effect
Performance values
Level of support to
competitive priority
Figure 4.
An example of critical
hurdle effect
Performance values
IJOPM the quality of the assessment. In that case quantitative performances should
16,8 also be treated as qualitative, calculating their absolute ratings on the basis of
the paired comparison procedure.
Absolute
Factory A B C D rating
Factory A B C D
Table XV.
The solid waste of Solid waste (tons)/
the factories production volume 115 10–4 15 10–4 80 10–4 40 10–4
For instance, referring to the example problem, the green image of a factory in
relation to the local community could be measured in quantitative terms
through a survey, based on a questionnaire, among a sample of people and
institutions of the area. But the cost and time required by this quantitative
measurement would be too much in relation to the cost of a less precise, but
effective, qualitative measure of the image of the factory, based on some
qualitative data – for instance, interviews and articles published in the local
newspapers and reviews, or number of complaints.
Managerial implications
The AHP is a flexible tool, as it can be applied to any hierarchy of performance
measures, whatever the number of levels, of manufacturing departments and of
performance measures there may be. However there are some assumptions that
have to be carefully considered before applying the AHP to performance
Table XVIII.
Factory A B C D The ratings of the
factories’ evironmental
Environmental compatibility rating 0.068 0.440 0.192 0.335 compatibility
Factory A B C D
Table XIX.
The overall ratings and
Overall rating 0.194 0.279 0.192 0.335
the corresponding
Rank 4 2 3 1 rank of the factories
IJOPM assessment. Such assumptions, if disregarded, can mislead managers about this
16,8 technique. Hence, before pointing out the major managerial implications of the
AHP, its most critical assumptions, already pointed out in the previous section,
are here summarized[41]:
• the manufacturing departments that are to be compared should be
116 homogeneous in terms of manufacturing competitive priorities and set of
performance measures on their responsibility;
• competitive priorities and performance measures should be
independent, not redundant and additive;
• the pairwise comparisons made by managers have to be fairly
consistent;
• the 1-9 preference scale allows the relative importance of competitive
priorities and performance measures to be expressed well.
On those assumptions the benefits of the application of the AHP to performance
measurement goes beyond the establishment of a rank among different
manufacturing departments. In fact the AHP framework allows the
information of a given rank to be increased, by giving in output also partial
calculations, such as the absolute ratings of the factories with respect to each
competitive priority, and by performing a sensitivity analysis to investigate the
stability of the rank, when there are changes, for instance, in the priority
weights of the manufacturing competitive priorities.
Also when the fit between the assumptions of the AHP and the reality is
inadequate, the AHP can support managers and management accounters, by
structuring a complex problem in an organized form, linking together
competitive priorities, performance measures and manufacturing
departments. Hence in those cases, the contribution of the AHP is in providing
a structure for the problem, rather than in providing optimal or even good
solutions.
The above considerations show that the use of the AHP can improve the
main objectives of a performance measurement system, that is, integration,
control, motivation and decision making.
With regard to integration, the AHP can:
• Encourage discussion among managers about the manufacturing
competitive priorities and performance measures, facilitating managers
to reach agreement on those that are critical for the company.
• Help managers to communicate the manufacturing competitive
priorities and the relative importance of performance measures to all
levels of the organizational str ucture of manufacturing, by
translating managers’ subjective judgements into quantitative terms.
This ensures a congr uence between individual actions and
manufacturing strategy.
As far as control is concerned, the AHP, by formally and systematically An AHP
considering all performance measures on the responsibility of a given framework
manufacturing department, makes it possible to:
• standardize and organize the control procedure, avoiding their
dependence on subjective and implicit judgements of managers and
management accountants;
117
• understand better the overall support of each department to manufactur-
ing strategy – and, thus, ultimately to the achievement of the overall
business strategy – by addressing trade-offs among different perfor-
mance measures (or competitive priorities).
As a consequence, the AHP may lead to the design of more effective systems of
people evaluation and reward.
With respect to motivation, the AHP makes the control mechanism more
transparent to department managers and employees by showing precisely all
performance measures against which they are evaluated. This drives people to
focus their attention on all manufacturing priorities and, for each priority, on
performances that contribute to its achievement. In particular, since the AHP
also takes into account qualitive measures, people are induced to consider
intangible performances, which are usually disregarded by performance
measurement systems. Furthermore, the AHP can encourage competition
among departments and cells.
Finally, the AHP can support the decision making of department managers
by indicating, for instance, priorities for operating improvement programmes,
supporting resources allocation, guiding the investments in technologies,
plants, equipment, etc.
In this article the AHP framework has been applied to assess and compare
the overall performance of several departments within the same company.
However, the same framework can also be used to benchmark manufacturing
performances against major competitors, by comparing manufacturing
departments of different companies. In that case a critical problem is the
difficulty in retrieving quantitative data relevant to competitors’ performances:
the problem can be addressed by the AHP, since it can deal with qualitative
measures.
Organizing committee:
Dr K.A.H. Kobbacy, Salford University (Chair)
Mr N. Proudlove, UMIST
Dr S. Vadera, Salford University
Chris Barrett, Operational Research Society
Scientific committee:
Mr H. Beck, University of Edinburgh
Professor A.H. Christer, Salford University
Professor R.H. Hollier, UMIST
Dr K. Kautz, Norwegian Computer Centre, Norway
Dr K.A.H. Kobbacy, Salford University
Dr E. Plaza, Universitat Autonoma de Barcelona, Spain
Dr Sam Steel, University of Essex
Professor H. Oesterle, University of St Gallen, Switzerland
Dr S. Vadera, Salford University
Professor C.A. Voss, London Business School