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The Toyota Production System is a paradox. On the one hand, every activity, connection, and production flow in a Toyota factory is rigidly scripted. Yet at the same time, Toyota's operations are enormously flexible and responsive to customer demand. How can that be? After an extensive four-year study of the system in more than 40 plants, the authors came to understand that at Toyota it's the very rigidity of the operations that makes the flexibility possible. That's because the company's operations can be seen as a continuous series of controlled experiments. Whenever Toyota defines a specification, it is establishing a hypothesis that is then tested through action. This approach--the scientific method--is not imposed on workers, it's ingrained in them. And it stimulates them to engage in the kind of experimentation that is widely recognized as the cornerstone of a learning organization. The Toyota Production System grew out of the workings of the company over 50 years, and it has never actually been written down. Making the implicit explicit, the authors lay out four principles that show how Toyota sets up all its operations as experiments and teaches the scientific method to its workers. The first rule governs the way workers do their work. The second, the way they interact with one another. The third governs how production lines are constructed. And the last, how people learn to improve. Every activity, connection, and production path designed according to these rules must have built-in tests that signal problems immediately. And it is the continual response to those problems that makes this seemingly rigid system so flexible and adaptive to changing circumstances.

A gifted project leader lacks significant new product development experience. The case highlights the issues and procedures related to defining the project strategy: organizing senior management approvals and support for creating a "heavyweight" team; aligning the disparate perspectives, interests, and biases of project members; and implementing best-practice tools for managing teams within the project. Creates a framework for establishing organizational design rules and key new product development processes, and also provides insights about models of leadership for new product development.

In 1997, Lifeline Systems continues to grow its service business to $32 million, 56% of the company's total revenues. More local hospital Lifeline programs turn over their monitoring service to Lifeline Central, expanding the company's subscriber base by 30%. The company decides to invest over $11 million in a new subscriber monitoring system to maintain its market leadership. At the end of 1998, Lifeline moves its corporate headquarters from Cambridge, MA to suburban Boston to lower real estate costs. Changes in the eldercare industry also spell growth: employers become interested in providing eldercare referral as an employee benefit, cuts in Medicare result in less home health care by nurses, and Lifeline forms strategic partnerships with the American Red Cross and an assisted-living community developer.

Describes the design and launch of an Internet venture. Focuses on the drivers of the venture's scalability and adaptability.

Most small business managers claim that cash management is their leading concern. Often walking a tightrope between growth and illiquidity, small business managers face different cash management challenges than their counterparts in larger companies. Compared to larger firms, small businesses often have under-staffed and under-trained accounting staffs, volatile cash flows dependent on a single product line, limited access to new capital, and a significant share of their net worth tied up in working capital. These limitations are often compounded by management's focus on growth, which can put additional pressure on the cash management system by increasing net working capital requirements.

Chantal Cookware is a small, private company with a 15-year record of success in the design, assembly, and sale of high-end cookware. It experiences serious setbacks when consumers' tastes shift from colorful enamel-on-steel products to commercial-style cookware. Thurlow must decide how to revitalize the business and considers several alternatives, including entering a lower priced niche or repositioning the existing product line. Includes color exhibits.

Display Technologies, Inc. (DTI) is a new joint venture between Toshiba and IBM Japan that is manufacturing the most advanced form of flat panel displays. With success in achieving significant production volumes, DTI has been asked to double its output as quickly as possible. Mr. Shima, DTI's president, must decide among three options, each of which has immediate and long-term strategic consequences.

Jim Sharpe, president of Extrusion Technology, describes the first five years at the aluminum extrusion company he purchased. He begins with day one as he introduced himself to the employees in 1987 and assured them of the company's continuity. Over the next two years, his efforts to make the company profitable included cost cutting, decertifying the union, and developing relationships with suppliers. Sharpe learned from mistakes in forecasting aluminum inventory and purchasing capital equipment for a new product line whose market never developed. At the end of five years, Extrusion Technology was profitable and well poised for growth.

Andy Youmans, executive vice president of CSSC, joins a group of U.S. executives on a tour of Japanese factories that practice the TPS. Three of the factories produce products similar to CSSC's, and even though they use similar equipment, they are significantly more productive. Once he returns to the United States, Youmans needs a plan to dramatically change his company, knowing that the three Japanese firms have significantly better performance (more than four times the revenues per employee). How can he replicate the Japanese companies' capabilities?

Connecticut Spring and Stamping Corp. (CSSC), a 50-year-old spring manufacturing and metal stamping firm, is experiencing slow sales growth and feeling the impact of global competition. The company has over 800 customers but little understanding of those customers' needs. They must improve manufacturing efficiency and respond to customer demands for higher quality, lower cost, and shorter delivery lead times. The company has a rich history of trying many management fads and now is exploring different methods of achieving higher quality. Andy Youmans, executive vice president responsible for this quality initiative, is contacted by the Toyota Supplier Support Center (TSSC), a world leader in manufacturing methodology, who offers to educate the CSSC plant in the Toyota Production System (TPS). Although short-term improvements are made, quality and delivery times worsen. It seems employees do not understand the reasons behind the new production methods, and Youmans is concerned about how to transfer what he has learned. The TSSC consultants suggest that Youmans go to Japan to visit companies that are practicing TPS principles.

After meeting with a mediator, Montagu and Davis decided their goals were not in accordance, and Davis left General Scanning. Montagu and Brosens wrote three-year objectives for the company and proceeded to search for a new professional manager. Chuck Winston took on the role of CEO/president with the goals of growth, profitability, consistency, and solid management. Winston decentralized the company by forming four separate divisions: Recorder Products, Laser Systems, Optical Scanning, and Laser Graphics. By the end of 1994, General Scanning was worth over $76 million, was showing a profit with a strong balance sheet, and had over 1,000 customers. Having turned around the company and grown it threefold, Winston and the founders need to decide what to do next: merge, acquire, do an IPO, or spinoff the successful Laser Systems division. There remained the haunting issue that most of the stock was held by the two founders. The case discussion challenges students to deal with the core problem of managing this technology company--that is, formally changing the roles of the founders by changing the ownership and board of directors.

Traces the development of Hewlett-Packard Co. from a small start-up company in 1938 to a world-class manufacturer of electronic instruments and computer products. Examines the challenges of starting and running a small company, including financing, human resources management, product strategy, human relations, and management succession. The creation of a unique and enduring set of values and a philosophy of running and growing a company, known as the "HP Way," is emphasized.

Describes the continuous flow process used to generate orange juice concentrate. Production involves several tightly coupled process steps with varying production rates and setup times. Given production constraints and customer requirements, management choices must be made to maximize the greatest contribution.

Designed to be used after Natural Blends, Inc.

Display Technologies, Inc. (DTI) is a new joint venture between Toshiba and IBM Japan that is manufacturing the most advanced form of flat panel displays. With success in achieving significant production volumes, DTI has been asked to double its output as quickly as possible. Mr. Shima, DTI's president, must decide among three options, each of which has immediate and long-term strategic consequences.

Jim Sharpe, 11 years after receiving his MBA from Harvard and working for others, has finally become his own boss and 100% owner of manufacturer of aluminum extrusions. After 10 months of an unfunded search, he acquires the business in an LBO and prepares to face his employees on the first day.

Jim Sharpe, 11 years after receiving his MBA from Harvard and working for others, has finally become his own boss and 100% owner of manufacturer of aluminum extrusions. After 10 months of an unfunded search, he acquires the business in an LBO and prepares to face his employees on the first day.

OXO, a kitchen tools and gadgets company, was started by a businessman who had 30 years of experience in the housewares industry. With his wife and son as founders, he creates a new niche in the gadgets industry for high-end gourmet stores. The company has headquarters in New York City, but it outsources product design to a NYC industrial design firm, manufacturing to Asia, and warehousing to a site in Connecticut in order to manage start-up costs and growth. Because of the veteran businessman's reputation and industry sense, the company grows quickly and in 1992 is sold for $6.2 million to a large housewares distributor, General Housewares. The original owners stay on as consultants to the parent company and decide to turn over management of the company to a Harvard MBA who also has extensive industrial design experience. Innovative product design is the key to OXO's success, and the company has worked exclusively with one design firm based on royalties of sold products. The new managing director initiates new product category programs for the bathroom, the garden, and home baking. He must coordinate the outsourcing of the design and development function.

Midnight Networks, Inc., is a small computer network validation company. This case describes how the five founders built their business from operations earnings and how they established "best practices" operational processes to run their firm successfully. Operational processes include developing a company procedures manual and assigning topics to specific people to maintain procedures; cross-training every employee in support and sales functions; employees entering weekly tasks and accomplishments on an online whiteboard that the whole company can view; group reviews of computer code for quality; performance reviews done by a committee of supervisor and peers. The company grows quickly, and a larger firm offers to buy it. Midnight Networks also has been considering going public. The founder must decide whether to go public or sell the firm to continue its growth.

A descriptive manual for how to manage the process of project management. Major sections are: 1) define and organize the project, 2) plan the project, and 3) track and manage the project. 12 processes are described in detail.