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In this first of a two‐part series, the methodology for the research is described. This took the form of a postal questionnaire carried out in conjunction with the Institute of Industrial Managers to establish the current situation. The results were compared with a similar study carried out in 1980. Work on the questionnaire was supplemented by a series of interviews and in‐company work. This included measurement of the movement of materials through the system and machine utilisation, the results and conclusions from which are presented. Part II of the series proposes a methodology for sustained improvement of production management systems.

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