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In most European countries a structural change from a production dominated towards a service oriented society is progressing. Companies increasingly consider services as means to gain competitive advantages in a global competition. In order to provide holistic, value-adding solutions while simultaneously guaranteeing high quality standards, production companies increasingly join forces with external services‘ providers. Models, methods and tools for service development are rare and in most cases immature. In the context of virtual services‘ development this leads to a dual set of simultaneous chal-lenges: an alignment of systematic services‘ and product development and the coordination of distributed R&D partners. The objective is to provide a meta-process that identifies all steps and decision points necessary to successfully develop innovative services. It is a result of combined service development and virtual enterprises‘/ networks‘ research.
The Aim of this article is to provide a framework which enhances the existing scope of manufacturing asset management by specifically addressing industrial services provided by external suppliers as an integral part of today’s manufacturing structures. Existing research shows that sourcing industrial services from specialized service organizations establishes complex and unique interdependencies and links total production efficiency to the performance of the external service suppliers. Within the context of the EU-Project InCoCo-S - “Innovation, Coordination and Collaboration in Service Driven Manufacturing Supply Chains” a standard business reference model with key focus on operation and integration of business related services (BRS) in the supply chain has been developed. Based on the service type retrofit this paper aims on the one hand to present the modules of the reference model and on the other hand to explain how the model can be used to enhance the retrofit business.
Technologiebasierte Leistungssysteme versetzen den Werkzeugbau am Hochlohnstandort Deutschland in Zukunft in die Lage, nachhaltige Wettbewerbsvorteile zu generieren. Dazu ist es allerdings erforderlich, nicht nur die Technologiebasis in Form von Transponder- und Sensortechnik in das Werkzeug zu integrieren, vielmehr ist es nötig, entsprechende neue Geschäftsmodelle für diese Leistungssysteme zu entwickeln. Außerdem ist sicherzustellen, dass die Geschäftsmodelle auf operativer Ebene auch mit der Technologie harmonieren und die gewonnenen Daten entsprechend in die Auftragsabwicklungsprozesse integriert werden. Der vorliegende Beitrag stellt potenzielle neue Geschäftsmodelle für den Werkzeugbau vor und skizziert einen Ansatz zur operativen Integration der benötigten Informationen in die Geschäftsprozesse.
Der vorliegende Beitrag baut auf den Arbeiten eines Forschungsprojekts auf. Das Forschungsprojekt 'TecPro - Geschäftsmodelle für technologieunterstützte, produktionsnahe Dienstleistungen des Werkzeug- und Formenbaus' wird mit Mitteln des Bundesministeriums für Bildung und Forschung (BMBF) innerhalb des Rahmenkonzepts "Forschung für die Produktion von morgen" (Förderkennzeichen 02PG1095) gefördert und vom Projektträger Forschungszentrum Karlsruhe, Bereich Produktion und Fertigungstechnologien (PTKA-PFT), betreut.
In diesem Beitrag werden die Ergebnisse aus einer Studie in der Papierindustrie vorgestellt. Dabei zeigt sich eine deutliche Korrelation zwischen guten Ergebnissen in der Effektivität und Effizienz des Zuverlässigkeitsmanagements und dem Unternehmenserfolg. Der Unternehmenserfolg – im Sinne einer hohen Umsatzrendite – kann zwar nicht allein auf einen entscheidenden Einflussfaktor zurückgeführt werden, da der Umsatz durch eine Vielzahl von Faktoren bestimmt wird. Die durchgeführten Analysen und Interviews innerhalb der Studie deuten allerdings darauf hin, dass in der Tat das operative Anlagenmanagement einen maßgeblichen Erfolgsfaktor darstellt, sich „Reliability“ in der Prozessindustrie folglich auszahlt. Überdies konnte gezeigt werden, wie sich Methoden und Verhaltensweisen von Instandhaltung und Produktion auf die Zuverlässigkeit von Anlagen und die Effizienz deren Bewirtschaftung auswirken.
In diesem Beitrag werden die aktuellen Aktivitäten im Forschungsprojekt „SiZu – Integration von Echtzeitsimulation und Zustandsüberwachung zur Bauteilprognose und Fehleranalyse für die Instandhaltung“ vorgestellt. Ziel des Projektes ist es, die bislang separat genutzten Funktionalitäten Condition-Monitoring und Echtzeitsimulationen in einem Analysewerkzeug (Condition- Analyser) für die Instandhaltung zusammenzuführen und damit Zustandsüberwachungssysteme um die Möglichkeit der Nutzung historischer Anlagendaten und Echtzeitsimulation zu erweitern. Neben der detaillierten Beschreibung der angestrebten Forschungsergebnisse und den daraus resultierenden Nutzungspotentialen für die Instandhaltung wird die zur Zielerreichung entwickelte Vorgehensweise vorgestellt und diskutiert.
One of the major tasks of operations managers is to boost uptime while simultaneously keeping budget. To meet this challenge they discover reliability-based management as strategic factor to improve performance. But which parameters are the key to “reliability excellence” and drive a company’s performance? What are the relevant levers to pull in reliability-based management?
To answer these questions McKinsey & Company partnered with Aachen University to launch a global reliability survey in process industries. Objective of the initiative is to provide a statistically proven picture of key factors that drive maintenance and reliability excellence. Furthermore benchmarks and best practices concerning overall operational performance will be identified. The study is based on a questionnaire-based approach which addresses all relevant departments within a company, complemented by best practice analyses.
This paper provides results of the survey. The results demonstrate that reliability pays off. Some unproven beliefs have been confirmed (e.g. a good reliability performance results in a low spare part inventory) but also surprises like a correlation between safety and performance were identified. The analysis also shows that structural differences like company size or geography do not influence reliability performance.
In the near future, tooling companies will offer their customers not just maintenance services, but complex remote service packages for their engineering asset management, which is the total management of physical – not financial – assets. The overall goal is to enhance the efficiency of the engineering asset, e.g. to reduce TCO, on the customers´ site by means of value creating partnerships. These partnerships may be, e.g. the classical output or reliability partnership, but also process optimizing partnerships or lifecycle partnerships. The process optimizing partnership offers, e.g. the optimization of the system’s performance or the output quality, an optimized ramp-up and restart procedure or optimization of the production process parameters. The lifecycle partnership, on the other hand, accompanies the intelligent tool-machine-system throughout the whole lifecycle, which includes, e.g. provision of spare parts during the entire usage phase, storing, refurbishment, recycling and even the support of relocation of production facilities. Intelligent remote services have great potential for realizing all these partnerships.
To realize such engineering asset-related partnerships, two major tasks have to be done. First, there has to be the intelligent tool-machine system, which delivers the information that is required for these services. And furthermore, this information has to be integrated into the maintenance processes, so that it is delivered at the right place and time and in the required form. Second, the activities and processes that are combined to the engineering asset-related partnerships have to be configured out of standardized service and process modules. Therefore configuration logic is essential.
The House of Maintenance
(2009)
In order to guarantee an efficient and effective employment of production equipment, it is essential to identify any possible potential for improving performance, not only in the production process, but also in supporting areas such as maintenance. One of the major tasks in increasing maintenance performance consists of systematically identifying the company’s most significant weaknesses in maintenance organisation and thus being able to implement improvements there where they are most needed.
But how is a company to tackle this important task? To answer this question, this paper describes an assessment and improvement approach, based on a capability maturity model (CMM). By means of this approach, the status-quo of a maintenance organisation can be analysed and its individual improvement opportunities identified.
Rebound Logistics
(2009)
Today, the flow of product returns is becoming a significant concern for many manufacturing companies. In this research area, three fundamental aspects of product returns need to be taken into consideration: First, companies become increasingly aware of the fact that product returns may offer an opportunity for enormous profit generation and for improving the competitive advantage of a manufacturing company when taking into account the accretive value of the products and technology. Second, the impact of green laws, legislative provisions and the increasing impact of a sustainable production management due to marketing aspects force companies to design and manage the reverse supply chain actively. Third, the importance of managing the reverse supply chains effectively will be enforced by the currently volatile economic climate. This paper outlines first results of designing a methodological framework for implementing an integrative reverse supply chain for manufacturing companies based on a type-specific Reverse Supply Chain Reference Model.
Due to shorter product life cycles the number of production ramp-ups is increasing, while customers have a soaring demand for more variable and individualized products. In the future, optimizing the production ramp-up will become an important differentiation criterion for companies. Considering the whole supply chain in the ramp-up process becomes therefore indispensable. This is what the presented research in this paper concentrates on. The intention of the research project is to develop a model of a supply chain in the production ramp-up stage. Through this model, approaches for optimizing the production ramp-up in the whole supply chain will be derived.
Further the research project concentrates on measuring the production ramp-up performance in the supply chain, showing the impact on economic and financial measures. The result of this research is an approach to align the tasks and objectives of Supply Chain Management with the tasks and objectives of ramp-up management in order to optimize the whole supply chain in the ramp-up stage.
Holistic PLM- Model
(2010)
Product Lifecycle Management (PLM) is a widely discussed topic concerning the increase of efficiency of product development in terms of time to market as well as customizing products to the different needs of customers worldwide adequately. Historically PLM focuses the early phases of the product’s lifecycle, namely the product development phase. Therein the roots of PLM are based in supporting the information logistics of product data: Consistent data sets should be available to all stakeholders in the different departments at all times. Due to the increasing product complexity PLM has to be extended in terms of the temporal dimension (not limited to product development phase) and systemic dimension (not limited to the information logistic aspect). In this paper the authors derive a holistic framework for Product Lifecycle Management by analysing existing integrated management approaches. The framework consists of four dimensions: PLM strategy, PLM process, Product structure and PLM IT-Architecture. The sustainability and benefits of the framework is demonstrated by applying the framework to the communication service provider industry (CSP).
Industrial companies face tremendous challenges to plan the resources needed to meet future market demands when implementing a PSS based solution portfolio. This paper deals with enhancing the PSS research landscape by presenting an approach to enable better resource-planning in PSS based businesses. In particular, a model is proposed which links resource structures with customer offerings. Linkages are implemented, which connect resources and their use in processes. The model contributes to better understand the complexity in resource structures and elements in the PSS and helps to better understand and describe the structural integration of resources in PSS. This is an important prerequisite for the planning of PSS and allows a qualitative and quantitative description of the service resources allocation enabling companies to build the competence needed to meet customer requirements. A case study based approach was applied for model development.
Industrial Service Providers (ISP) are exposed to constantly raising competitive pressures regarding both cost and performance aspects. The massive challenges caused by the current worldwide financial and economic crisis even intensified the need for process optimizations aimed at increasing the productivity of service production. To reach this goal the evaluation and elimination of waste in their production processes becomes a crucial ability for ISPs. This paper proposes a new approach for increasing productivity in service production processes using a generic measurement model for the detection and evaluation of waste. The model is based on established lean management principles, but tailored to the specifics of ISPs by adopting a customers’ perspective to track down and eliminate waste. The evaluation builds on an in-depth-analysis of particular types of waste in the industrial service production processes. Viewed from the customers’ perspective and taking into account the specific characteristics of services (e.g. intangibility, heterogeneity, inseparability, and perishability) and service production (e.g. volatile demand, a tendency to over-capacity, and limits to planning) the approach employs a service blueprint reference model to then determine the different types of waste in the various parts of the service production process.
Manufacturing companies of the machinery and equipment industry find themselves more than ever exposed to a rapidly changing competitive environment. In particular, the resulting diversity of planning and control processes confronts organisations and information systems with a significant coordination effort. To this day, planning and execution of order processing – from offer processing to the final shipment of the product – is still a part of the production planning and control (PPC), which is almost entirely integrated into information systems. Though, in order to manage dynamic influences on processes within order processing, there can be found a deficiency in the processing of decision-relevant and real-time information. Partly, the reason for this is a missing or incorrect feedback of process relevant data, so that the planning results, gained by the use of information systems, differ to the current process situation.
The concept of Manufacturing Resource Planning (MRP II) still represents the central logic of production planning and control. However, the centralised and push-oriented MRP II planning logic is not able to plan and measure dynamic processes adequately, which, due to diverse disturbances, often occur in production environments. Furthermore, specific weaknesses of MRP II-based systems are the lack of support for order releases, the planning principle based on average values and the successive planning method as well as the use of limited partial models. As a result a successive planning method leads to a dissection of PPC-tasks into smaller work packages and so strides away from a holistic approach and the achievement of an optimal solution. Similarly, a planning, focusing on a general business objective system, using a partial planning approach due to isolated considerations is not possible. Insufficient consideration of the current load horizon and the current capacity utilization, non-existing or delayed feedback on order progress as well as faults and poor availability and transparency of information can be named as further weaknesses of MRP II-based systems.
Remote services are services enabled by information and communication components and therefore do not require the physical presence of a service technician at the service object to provide a task. The impact of remote service on the capital goods industry has been increasingly significant over the recent yeas. Still many companies struggle with developing and implemenling successful business model, for remote service. This leads to a lot of unaccomplished benefits for the customer as well as for the companies themselves. A survey throughout companies in Ihe industrial machine and plant production sector was conducted in order to determine what successful companies do differently from those that cannot efficiently implement remote service business models.
The study presented in this chapter identifies key suceess factors of companies that effectively implemented remote services for their products. In order to identify the successful companies a scale for measuring remote service success was developed. Only by the use of this scale further findings regarding the success factors were possible. Key findings include the fact that successful companies actively market their remotle service to their customers. Generally they try to approach their remote service business from the operating company's perspective.
Maximising economies of scale in individualised production is a vital issue for producing companies in high wage countries. A decisive enabler for this is the management of product and process complexity by systematic standardisation. Due to the strong and far-reaching impact of complexity on the value added chain, its management requires an integrative consideration of the entire product and production system.
The following paper introduces a methodology facing this challenge. The core element of this methodology is an integrative and complexity-focused assessment model. This assessment model has been validated experimentally by analysing key company data from more than 50 German toolmaking firms. Findings of this empirical investigation are presented in this paper.
Assets of integrated production systems, especially in the heavy industry, are facing high requirements in terms of reliability and availability. In case of component breakdown, the operating firm is confronted with high costs due to downtime and loss of production. Modern maintenance concepts in combination with advanced technologies can help to improve the plant availability and reduce the downtime costs caused by unplanned breakdowns. Against this background, the research institutes FIR and IMR from RWTH Aachen University, Germany, are collaborating within the research project “SiZu”. This project deals with the integration of condition monitoring system and real time simulation to assess the condition of components and to support failure cause analysis.
Aufgrund kürzer werdender Produktzyklen und steigender Produktvielfalt werden produzierende Unternehmen mit einer zunehmenden Anzahl von Produktanläufen konfrontiert. Ziel aktueller Forschungsaktivitäten ist es daher, anlaufintensive Unternehmen zu befähigen, verlässliche Produktionsprogramme in kurzer Zeit zu erstellen. Lerneffekte sollen genutzt werden können ohne Diversifikationseffekte zu vernachlässigen. Zur Erreichung dieser Zielsetzung wird ein Modell für eine kybernetische PPP bei Produktanläufen entwickelt.
For a considerable time, European companies in the capital goods industry experience stagnating growth in material goods markets. Moreover, increasing international competition forces European companies to improve their market position. In order to stay successful, an increasing number of companies adapt their businesses from manufacturing to service provider. Unfortunately, the number of companies who manage to turn their portfolio change into a competitive advantage is comparatively low. Therefore, this paper focuses on the development of a framework for the positioning as industrial services provider. Besides, it provides support for management in shaping the changes that occur with the transformation.