Characterizing the product-process architecture of competitive firms: A case study of a Japanese manufacturing firm

This research paper explores the product-process architecture characterizing the manufacture of competitive products by Japanese firms. Furthermore, the research focuses on manufacturing that is carried out by Japanese firms and is based on modular product-process architecture. This research focus is selected because it represents an atypical scenario; Japanese manufacturing tends to be competitive when based on integral product-process architecture. The research was conducted using a case study of TOTO, a Japanese firm that is a leader in the manufacture of toilet units. In recent years the integral product-process architecture of TOTO has shifted towards a modular architecture. At the same time, TOTO has also achieved a competitive position and has manufactured toilet units with world-class performance. When examining the characteristics of TOTO´s product-process architecture in closer detail, it appears that TOTO retained integral architecture for two of its manufacturing stages; product inspection and product testing. The stages of product inspection and product testing are considered pivotal in achieving TOTO´s competiveness. In particular, the human involvement and ongoing optimization measures resulting from these stages provide a unique quality advantage, which cannot be duplicated by other manufacturers. TOTO has adopted a product-process architecture that while predominantly modular, involves inspection and testing stages that are based on integral architecture. Characterization of an architecture which is linked with competitiveness was carried out for the single case of TOTO. This is a limitation of the research and there is scope for increasing the number of cases investigated and covering a range of firms, industries and technologies. This information on architecture types can elucidate the product-process architecture associated with competitive performance for various scenarios, including the development of emerging technologies.