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Metrics and Performance Measurement in Operations Management:


Dealing With the Metrics Maze

Article in Journal of Operations Management · June


2004
DOI: 10.1016/j.jom.2004.01.004

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Journal of Operations Management 22 (2004) 209–217

Metrics and performance measurement in operations


management: dealing with the metrics maze
Steven A. Melnyk∗, Douglas M. Stewart, Morgan Swink
Department of Marketing and Supply Chain Management, The Eli Broad Graduate School of
Management, Michigan State University, East Lansing, MI 48824-1039, USA
Accepted 16 January 2004

Abstract
Metrics provide essential links between strategy, execution, and ultimate value creation. Changing competitive dynamics
are placing heavy demands on conventional metrics systems, and creating stresses throughout firms and their supply chains.
Research has not kept pace with these new demands in an environment where it is no longer sufficient to simply let metrics
evolve over time—we must learn how to proactively design and manage them. The intent of this paper is to convey the
importance and need for metrics-related research. An outline of the important characteristics of the metrics research topic is
provided. Specifically, we address the functions of metrics; their focus and tense; their operational and strategic contexts; as
well as discuss the distinction between metrics, metrics sets and metrics systems. Some initial theoretical grounding for the
research topic is provided through agency theory. We conclude with a discussion of the intent and process of the special issue,
and introduction of the associated articles.
© 2004 Elsevier B.V. All rights reserved.
Keywords: Metrics; Performance measurement; Operations management

1. The metrics challenge “Given our mission, how is our performance going
to be defined?” (Magretta and Stone, 2002, p. 129)
One of the most powerful management disciplines, The quote from Magretta and Stone (2002) sug-
the one that more than any other keeps people fo- gests that metrics and performance measurement are
cused and pulling in the same direction, is to make the critical elements in translating an organization’s
an organization’s purposes tangible. Managers do mission, or strategy, into reality. Metrics and strat-
this by translating the organization’s mission—what egy are tightly and inevitably linked to each other.
it, particularly, exists to do—into a set of goals and Strategy without metrics is useless; metrics without a
performance measures that make success concrete strategy are meaningless. The importance of metrics
for everyone. This is the real bottom line for every has been long recognized. Manufacturing and man-
organization—whether it’s a business or a school or agement consultant Oliver Wight almost 30 years ago
a hospital. Its executives must answer the question, offered the oft-repeated maxim, “You get what you
inspect, not what you expect.” Every firm, every ac-
∗ Corresponding author. Tel.: +1-517-353-6381. tivity, every worker needs metrics. Metrics fulfill the
E-mail address: melnyk@msu.edu (S.A. Melnyk). fundamental activities of measuring (evaluating how

0272-6963/$ – see front matter © 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jom.2004.01.004
210 S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–
217
we arc doing), educating (since what we measure is with measuring supply chain performance. The 2002
what is important; what we measure indicates how POMS National Conference included a special session
we intend to deliver value to our customers), and focusing on performance measurement. In late 2002,
direct- ing (potential problems are flagged by the KPMG in conjunction with the University of Illinois
size of the gaps between the metrics and the at Champagne undertook a major research initiative
standard). Yet, per- formance measurement continues aimed at funding and encouraging research in perfor-
to present a chal- lenge to operations managers as mance measurement (to the tune of US$ 2.8 million).
well as researchers of operations management. Finally, the January 2003 Harvard Business Review
Operating metrics are of- ten poorly understood and case study focused on the miscues and disincentives
guidelines for the use of metrics arc often poorly created by poorly thought out performance measure-
articulated. ment systems (Kerr, 2003). Why the increasing inter-
As a focus of research, little attention has been de- est? We believe the answer is in the business environ-
voted to this topic within the field of operations man- ment faced by today’s operations managers. Today’s
agement. A great deal of what we currently know environment is characterized by: (1) “never satisfied”
about metrics comes from the managerial literature customers (McKenna, 1997); (2) the need to manage
(e.g., Brown, 1996; Cooke, 2001; Dixon et al., 1990; the “total” supply chain, rather than only internal
Kaydos, 1999; Ling and Goddard, 1988; Lynch and factors; (3) shrinking product life cycles; (4) more
Cross, 1995; Maskell, 1991; Melnyk and Christensen, (but not necessarily better) data; and (5) an increasing
2000; Melnyk et al., in press; Smith, 2000; Williams, number of alternatives. These dynamics make static
2001). While there are numerous examples of the use metrics systems obsolete, and call for new perfor-
of various metrics, there are relatively few studies mance measures and metrics approaches that go be-
in operations management that have focused on the yond simple reporting to create means for identifying
development, implementation, management, use and improvement opportunities and anticipating potential
effects of metrics within either the operations man- problems. Further, metrics are now seen as an im-
agement system or the supply chain. Nascent exam- portant means by which priorities are communicated
ples can be found in the research of Beaumon (1999), within the firm and across the supply chain. Metrics
Leong and Ward (1995), Neely (1998), Neely et al. misalignment is thought to be a primary source of in-
(1994, 1995), and New and Szwejczewski (1995). efficiency and disruption in supply chain interactions.
We should point out that topic of metrics as dis- Given this environment, the research challenge is
cussed by managers differs from the topic of mea- to better understand the roles and impacts of metrics
surement as typically discussed by academics. This is in operating systems, and using this knowledge to de-
primarily a byproduct of different priorities between sign metrics systems and guidelines that provide clar-
these groups. The academic is concerned with defin- ity of purpose, real-time feedback and predictive data,
ing, adapting and validating measures to address spe- and insights into opportunities for improvement. In
cific research questions. The time required to develop addition, these new metrics systems need to be flex-
and collect the measures is of less importance than ible in recognizing and responding to changing de-
the validity and generalizability of the results beyond mands placed on the operating system due to product
the original context. Managers face far greater time churn, heterogeneous customer requirements, as well
pressures, and are less concerned about generalizabil- as changes in operating inputs, resources, and perfor-
ity. They are generally more than willing to use a mance over time.
“good enough” measure if it can provide useful in- By way of introducing this special issue on perfor-
formation quickly. However, as long as the difference mance measures and operating metrics, in the
in priorities is recognized there are undoubtedly many remain- ing sections of this article we:
lessons academic measurement experts can contribute
to managers’ understanding of metrics. • Identify the defining elements and different types
Recent indicators suggest that metrics and perfor- of metrics.
mance measurement are receiving more attention. • Position metrics within the operations management
In 1999, the Education and Research Foundation of research environment.
APICS commissioned a research program dealing
S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–217 211

• Identify the special research challenges associated values of other stakeholders in the process. For exam-
with metrics. ple, worker safety-oriented metrics are important, but
• Introduce the articles that comprise the special is- indirectly related to customer value.
sue.
Ultimately, the goal of this special issue is to direct,
2. The fundamental need for metrics
shape, and encourage research into this very
important topic area.
Metrics provide data refinement. As the volume of
inputs increases, through greater span of control or
1.1. Defining metrics—an overview growing complexity of an operation, data manage-
ment becomes increasingly difficult. Metrics provide
A metric is a verifiable measure, stated in either a means of distilling the volume of the data while si-
quantitative or qualitative terms and defined with re- multaneously increasing its information richness. Op-
spect to a reference point. Ideally, metrics are consis- erations need these functions in order to operate ef-
tent with how the operation delivers value to its cus- fectively and efficiently on a day-to-day basis.
tomers as stated in meaningful terms. Finally, metrics exist as tools for people. Ultimately,
This definition identifies several critical elements. the actions people take and the decisions they make
First, a metric should be verifiable, that is, it should determine the degree and nature of value that an op-
be based on an agreed upon set of data and a eration creates. These actions and decisions can be
well-understood and well-documented process for greatly influenced by metrics.
converting this data into the measure. Given the data Metrics provide the following three basic
and the process, independent sources should be able functions:
to arrive at the same metric value. Second, metrics • Control: Metrics enable managers and workers to
are measures. They capture characteristics or out- evaluate and control the performance of the re-
comes in a numerical or nominal form. In order to sources for which they are responsible.
interpret meaning from a metric, however, it must be • Communication: Metrics communicate perfor-
compared to a reference point. The reference point
mance not only to internal workers and managers
acts as a basis of comparison, and can be an absolute
for purposes of control, but to external stakeholders
standard or an internally or externally developed stan-
for other purposes as well (e.g., Wall Street, the
dard. Standards can be based on past metric values or
EPA or to a bank). Many times stakeholders and
based on metric values for a comparable process
users of metrics do not understand the workings
(e.g., a “benchmark”). Zero defects would be an
and processes of a firm or operation, nor do they
absolute standard, for example, as would be 100%
need to. Well-designed and communicated metrics
utilization. An operating budget is an internally
provide the user a sense of knowing what needs
developed stan- dard, whereas environmental
to be done without necessarily requiring him/her
performance might be compared to external standards
to understand the intricacies of related processes.
published by the Envi- ronmental Protection Agency
Poorly developed or implemented metrics can lead
(EPA). Because metrics are expressed relative to
to frustration, conflict, and confusion.
some reference point, they encourage comparison by • Improvement: Metrics identify gaps (between per-
the users of the metric or by external parties (as in the formance and expectation) that ideally point the
case of ISO 9000 auditors). way for intervention and improvement. The size of
It is generally desirable that a metric be expressed
then gap and the direction of the gap (positive or
in meaningful terms. If metrics are to be effective,
nega- tive) provide information and feedback that
they must be understood—they must make sense to
can be used to identify productive process
the per- son using the metrics. In addition, metrics
adjustments or other actions.
should be value-based. That is, a metric should be
linked to how the operation delivers value to its There are dynamic tensions inherent in requiring
targeted customers. Naturally, not all metrics will be one system to perform multiple functions. One such
directly related to customer value. Metrics may tension stems from the desire to change metrics in re-
also be related to the
212 S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–
217
sponse to new strategic priorities, and the desire to often use metrics in this way. Many of the cost-based
maintain metrics to allow comparison of performance metrics encountered in firms belong to this category.
over time. This tension will dictate the metrics life Similarly, many of the accounting based information
cycle. Moreover, as the metrics reflect underlying pri- systems observed in many firms typically generate
orities and decisions, metrics-related stress between outcome-based metrics.
various parties is often simply the first indicator of In contrast, a predictive use of a metric is aimed at
un- observed, unresolved conflicts between the increasing the chances of achieving a certain
customer, strategy, and operations of the firm. objective or goal. Predictive metrics are associated to
aspects of the process that will result in the
outcomes of inter- est. If our interest is in reducing
lead time, then we might assess metrics such as
3. A metrics typology
distance covered by the process, setup times, and
number of steps in the pro- cess. Reductions in one
One source of complexity regarding the study of
or more of these areas should be reflected in
metrics is the variety of different types of metrics that
reductions in lead time. An emphasis on identifying
researchers and managers encounter. We suggest that
and using metrics in a predictive way is relatively
various metrics can be readily classified according
new. Predictive metrics are appropriate when the
to two primary attributes: metrics focus and metrics
interest is in preventing the occurrence of problems,
tense. Metrics focus pertains to the resource that is
rather than correcting them.
the focus of the metric. Generally, metrics report
Combining of these two metrics attributes
data in either financial (monetary) or operational provides
(e.g., oper- ational details such as lead times, four distinct types of metrics:
inventory levels or setup times) terms. Financial financial/outcome, financial/predictive,
metrics define the perti- nent elements in terms of operational/outcome, and oper- ational/predictive (
monetary resource equiva- lents, whereas operational Scheme 1). These different cat- egories appeal to
metrics tend to define ele- ments in terms of other different groups within the firm. Top managers,
resources (e.g., time, people) or outputs (e.g., for example, are typically most in- terested in
physical units, defects). The second attribute, metrics financial/outcome. In contrast, operations managers
tense, refers the how the metrics are intended to be and workers are most likely interested in
used. Metrics can be used to both to judge outcome operational/predictive or operational/outcome metrics
performance and to predict future per- formance. An since these two sets pertain to the processes that these
outcome-oriented use of a metric im- plicitly 4. Levels must
managers of metrics
manage and change.
assumes that the problems and lessons uncov- ered
from a study of past outcomes can be applied to The term, “metrics” is often used to refer to one of
current situations. That is, by studying the past, we three different constructs: (1) the individual metrics;
can improve the present. In general, managers who (2) the metrics sets; and (3) the overall
monitor and reward activities and associated person- performance measurement systems. These terms are
nel use metrics in an outcome-based way. Executives often used in-

Scheme 1. Metrics typology.


S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–217 213

terchangeably, thus contributing to the confusion. We ensure that at every stage that the objectives set at the
suggest that recognition of the different levels of met- higher levels are consistent with and supported by the
rics and their interactions is important for the metrics and activities of the lower levels. In contrast,
research and design of metrics. coordination recognizes the presence of interdepen-
At the highest level, the performance measure- dency between processes, activities or functions.
ment system level integrates. That is, it is respon- Coordination deals with the degree to which the met-
sible for coordinating metrics across the various rics in various related areas are consistent with each
functions and for aligning the metrics from the other and are supportive of each other. Coordination
strategic (top management) to the operational (shop strives to reduce potential conflict that can occur
floor/purchasing/execution) levels. For every activity, when one area focuses on maximizing uptime (by
product, function, or relationship, multiple metrics avoiding setup and running large batches) and another
can be developed and implemented. The challenge focuses on quality and flexibility. Coordination tries
is to design a structure to the metrics (i.e., grouping to maintain an equivalence of activities, goals, and
them together) and extracting an overall sense of per- purpose across departments, groups, activities and
formance from them (i.e., being able to address the processes.
question of “Overall, how well are we doing?”). To date, most research and managerial attention
Several different approaches have been has
proposed focused on performance measurement systems or on
for developing such an integrative system. These individual metrics. Melnyk et al. (in press) suggest
in- clude: (1) the balanced scorecard, as presented that these two levels are not sufficient by themselves.
by Kaplan and Norton (1992, 1996, 2001) and There exists another metrics construct—the metrics
elaborated on by others (e.g., Ittner and Larcker, set. The metric set consists of the metrics assigned by
1998); (2) the strategic profit impact model a higher level of management to direct, motivate and
(otherwise known as the Dupont model (Lambert and evaluate a single person in charge of a specific
Burduroglu, 2000); and activity, process, area, or function. The metrics set
(3) the theory of constraints (TOC) measurement is critical because it is often the relevant unit of
sys- analysis, and because the scope and complexity of
tem (Lockamy III and Spencer, 1998; Smith, 2000 an individual’s metrics set can be viewed as a load
). Each of these major systems has strengths and imposed upon that person’s finite mental capacity.
weak- nesses. For example, the balanced scorecard These three levels of metrics are linked. At the base
excels at its ability to force top management to is the individual metric, the building block. Individual
recognize that multiple activities must be carried out metrics are aggregated to form various metrics sets.
for corporate success and the management and Each set directs, guides, and regulates an individual’s
monitoring of these activities must be balanced. The activities in support of strategic objectives. Coordinat-
strategic profit im- pact model provides the ing and managing the development of the various
operations manager with a mechanism, whereby indi- vidual metrics and the metrics sets is the
operational improvements such as reductions in performance measurement system.
inventory—changes of interest to the operating 4.1. Positioning metrics within the research
personnel—can be translated into its impact on environment
financial performance, changes of interest primar- ily
to top management. Finally, the TOC approach is There has long been recognition of metrics and its
attractive because of its ability to simplify the perfor- importance within the operations management field.
mance measurement problem and reduce the number Wickham Skinner in 1974 identified simplistic perfor-
of measures and areas actively and continuously mon- mance evaluation as being one of the major causes for
itored by top management. factories getting into trouble (Skinner, 1974). Subse-
The performance measurement system is quently, Hill (1999) recognized the role and impact
ultimately of performance measures and performance measure-
responsible for maintaining alignment and ment systems in his studies of manufacturing strategy.
coordi- nation. Alignment deals with the
maintenance of consistency between the strategic
goals and metrics as plans are implemented and
restated as they move from the strategic through the
tactical and operational stages of the planning
process. Alignment attempts to
214 S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–
217
In these and other studies, metrics are often viewed which to view the role of metrics in operations man-
as being part of the infrastructure or environment in agement. This theory states that the degree of interde-
which manufacturing must operate. pendence and the nature of interactions among func-
However, while we have recognized the role of tional specialists within an organization are influenced
met- rics as an influencing factor, there is still a need by the nature of the collective task they seek to
to posi- tion the topic of metrics within a theoretical accom- plish. In dynamic environments involving
context—a framework that gives metrics a central rapid prod- uct change and high degrees of
role. One such theoretical framework is agency heterogeneity in cus- tomer requests, agents
theory. responsible for different func- tional aspects of order
Agency theory applies to the study of problems taking, processing, and fulfill- ment become more
aris- and more dependent on each other for information
ing when one party, the principal, delegates work necessary to complete their respec- tive tasks. This
to another party, the agent (Eisenhardt, 1989a; Lassar theory has implications for the design of metrics
and Kerr, 1996). The unit of analysis is the systems. For example, questions such as “How
metaphor of a contract between the agent and the should metrics reflect the interdependencies of
principal. Prior studies using agency theory as the different functional areas?” could be posed. And fur-
theoretical frame- work have used “coordination ther, “How should the rotation or change in metrics
efforts” (Celly and Frazier, 1996), “control” ( be associated to the dynamics of demands placed on
Anderson and Oliver, 1987), and “management” ( the operating system?” These types of research
McMillan, 1990) as the unit of analysis. questions start to get at the coordination attributes of
There are numerous factors and variables that higher or- der performance measurement systems
in- raised earlier in this article.
fluence the most efficient “contract” in the We have in several places noted that metrics
dyadic relationship between a principal and agent. provide
These include the information systems (Eisenhardt, a vital linkage between intended strategies and actual
1989a), outcome uncertainty (Eisenhardt, 1989a), execution. This notion harkens to theories of strategic
risk aver- sion (Anderson and Oliver, 1987; Celly fit. Skinner (1969) offered one of the earliest opera-
and Frazier, 1996), programmability (Eisenhardt, tions management perspectives on strategic fit as he
1989a), and the relationship length (Eisenhardt, argued the need for strategic fit between manufactur-
1989a; Celly and Frazier, 1996). ing goals and decisions and other functional and cor-
Within operations management, agency porate strategies. Wheelwright (1984) further defined
theory the notion of strategic fit, stating the need for consis-
has been used to study such topics as tency between operations strategy and business strat-
decentralized cross-functional decision-making ( egy, other functional strategies, and the competitive
Kouvelis, 2000), group technology (Beh-Arieh, environment, respectively. While the need for strate-
1999), international manufacturing (Change, 1999), gic fit is recognized, how to go about achieving it has
scheduling (Gu, 1997; Kim, 1996), and inventory received less attention in the operations strategy liter-
management (Allen, 1997). Yet, what makes agency ature. Taking strategy fit theory as the frame of ref-
theory so attractive is that the recognition that in erence for the study of metrics might lead to insights
most organizations the concept of a contract as a into the role of metrics in achieving fit, and again, the
motivating and control mechanism is not really implications of strategy fit for the design of metrics
appropriate. Rather, the contract is re- placed by systems.
the metric (Austin, 1996). It is the metric that An information processing perspective (Galbraith,
motivates and directs; it is the metric that en- 1973) offers yet another potentially rewarding way to
ables principals to manage and direct the activities look at metrics. Presumably, a richer “metrics set” cre-
of their various agents. The development, selection, ates the basis for richer communications among de-
use, and refinement of metrics becomes a major con- cision makers, workers, strategy representatives, and
cern of both principals and agents. Consequently, customers of a process. However, there may be limits
agency theory provides a potentially interesting and to the organization’s (as well as individuals’) ability
useful theoretical context for operations management to process larger sets of metrics, and increasing num-
researchers to analyze this critical topic.
Dependency theory (Pfeffer and Salancik, 1978
)
might also be seen as a potentially fruitful lens
through
S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–217 215

bers of metrics could lead to greater conflict in the • Assessing consistency of metrics, both within the
implied priorities, as well as greater equivocality re- set of metrics being used and between the metrics
garding future actions. Given this apparent trade-off and corporate strategy (and the potential effects at-
between metrics set richness and complexity, an in- tributable to consistency or the lack of consistency
formation processing theoretical view could stimu- within the metrics).
late research into questions regarding the optimal size • Implementing performance measurement systems.
of a metrics set, or perhaps the optimal combination • Changing performance measurement system or
of outcome and predictive metrics included in the metrics over time.
set. • Measuring performance of product/process design
Linkage research in services, beginning with the processes.
work of Schneider et al. (1980) and more recently re- • Integrating environmental issues into the perfor-
viewed in Pugh et al. (2002) has focused on validat- mance measurement systems.
ing and quantifying perceived relationships between • Integrating metrics with the real or perceived
internal actions of a firm (such as particular human reward
resources practices) and important strategic outcomes structure.
(such as customer satisfaction and profitability). This • Assessing performance measurement and metrics
research may be particularly applicable to addressing within services and manufacturing settings.
such questions as “How does one derive a predictive Papers that were submitted for the special issue
metric?” and “Is a perceived predictive metric truly were subjected to an initial review by the co-editors to
predictive?” It may also help in illuminating the dif- assess the compatibility of the topic addressed by the
ferences between the metrics system as conceived by paper with the theme and focus of the special issue.
management and its actual structure. This will be par- Papers that did not pass this initial screen were, at the
ticularly relevant in understanding the relationships authors’ discretion, forwarded to the editor of the
between metrics that are not mathematically derived, Journal of Operations Management to be included in
such as when metrics interact through a lens of the normal review process for the journal. Of 10
altered behavior. papers submitted, 8 passed this initial review. These
eight papers were then subject to a normal double-
4.2. Overview of the special issue blind review process with three being accepted for
publication.
The first paper is “An exploratory study of
As can be seen from the preceding discussion,
perfor-
metrics and performance measurement is inherently a
mance measurement systems and relationships
complex topic. There is a need for research intended
with performance results” by James Evans. Evans
to better structure and to appropriately simplify the
uses the metrics framework provided by the Malcolm
analysis of this topic. These and other factors formed
Baldrige Award, which is similar to that of the
the motivation for this special issue.
balanced score- card to conduct an empirical
The announcement for this special was framed in
investigation of the re- lationship between the scope
very broad terms. Both theoretical and empirical pa-
or types of metrics used and customer, financial and
pers, as well as rigorous case studies, were invited.
market performance. The paper addresses issues
Cross-functional studies were particularly encouraged.
relating to both metrics and the metrics system.
Suggested topics for the special issue included: The second paper by Shinn Sun is “Assessing
• Assessing the impact of operating/predictive met- joint
rics on system performance. maintenance shops in the Taiwanese army using
• Evaluating the relationship between financial and data envelopment analysis”. This paper is application
operating metrics. ori- ented, and in it Sun develops a DEA-based
• Measuring performance within the supply chain perfor- mance assessment tool to evaluate the
environment—practices, challenges, problems and performance of multiple similar functional units, and
opportunities. identify op- portunities for improvement. The tool
is applied to a collection of maintenance shops to
demonstrate its usefulness. Sun’s tool directly
addresses two of the functions of metrics: control
through setting objective
216 S.A. Melnyk et al. / Journal of Operations Management 22 (2004) 209–
217
standards and assuring comparability of the results; zona State University; Janet L. Hartley, Bowling Green
and improvement through identifying areas of relative State University; Nancy Lea Hyer, Vanderbilt Univer-
inefficiency. Indirectly, the model supports the third sity; Jay Jayaram, University of Oregon; Chris Mc-
function of communication in that it identifies simi- Dermott, Rensselaer Polytechnic Institute; Linda G.
lar but more efficient functional units to communicate Sprague, CEIBS; Srinivas Talluri, Michigan State Uni-
with. versity; Shawnee Vickery, Michigan State University;
The final paper “Perceptual measures of perfor- D.B. Waggoner, Cambridge University; Ravi Behara,
mance: fact or fiction?” is from Mikko Ketokivi and Florida Atlantic University; Rohit Verma, University
Roger Schroeder. In it the authors investigate the reli- of Utah; Anthony Ross, Michigan State University;
ability and validity of perceptual measures of perfor- Daniel Krause, Arizona State University.
mance. They introduce and empirically demonstrate
a method for using multi-informant survey data, and
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