Requisites for applying adaptive control of safety lead time

Purpose A fundamental manufacturing challenge is how to dimension safety buffers effectively, particularly in today’s challenging competitive environment with increased focus on delivery capability and cost-efficiency. An adaptive approach is suggested to overcome such challenges, but no approach is effective unless applied. The purpose of this study is to explore the requisites for applying adaptive control of safety lead time in manufacturing companies. Design/methodology/approach An interactive, case-based research approach identified requisites – practical aspects to consider – for developing and applying adaptive control of safety lead time among four manufacturing companies. Findings A framework was developed comprising nine propositions on interlinked requisites for understanding cause-and-effect relationships, metrics and measuring, balancing performance variables and organizing for control. The framework is the first step of theory-building. Research limitations/implications The framework complements the literature beyond the conceptual idea of an adaptive control approach, positioned within the production planning process. Extending performance management literature to safety buffer control contributes to understanding and terminology. A metric, balancing delivery capability risk and cost risk to support application, is proposed. Practical implications The framework, with provided examples, enables practitioners to understand how to apply adaptive control of safety lead time, thereby increasing the potential real-world impact on delivery capability and cost. Originality/value An interactive and longitudinal research approach enabled deep insights into the practical development of applying adaptive control of safety lead time.