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A Methodology Based on Theory of Constraints' Thinking

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A Methodology Based on Theory of Constraints' Thinking A Methodology Based on Theory of Constraints’ Thinking Processes for Managing Complexity in the Supply Chain vorgelegt von Master of Science Şeyda Serdar Asan aus Istanbul, Türkei von der Fakultät V – Verkehrs- und Maschinensysteme der Technischen Universität Berlin zur Erlangung des akademischen Grades Doktor der Ingenieurwissenschaften - Dr.-Ing. - genehmigte Dissertation Promotionsausschuss: Vorsitzender: Prof. Dr. Dietrich Manzey Gutachter: Prof. Dr.-Ing. Joachim Herrmann Gutachter: Prof. Dr.-Ing. Frank Straube Tag der wissenschaftlichen Aussprache: 30 Oktober 2009 Berlin 2009 D 83 Acknowledgements This thesis is the final product of my PhD studies at the Department of Quality Sciences of TU Berlin. This whole process has been an invaluable experience enabling me to learn and grow, both personally and academically. I am grateful to many people for their help, guidance, encouragement, inspiration, friendship, and patience throughout the course of this study. I would like to express my deepest gratitude to Prof. Dr.-Ing. Joachim Herrmann, my advisor, for his professionalism, wisdom, kindness, patience, trust, and also for the encouragement of initiative and freedom of thought. I come out of from this experience so much richer and stronger in many ways. I am grateful to Prof. Dr.-Ing. Frank Straube, my co-advisor, for his interest in my thesis and valuable comments and suggestions. I thank Prof. Dr. Dietrich Manzey, the chair of the advisory committee, for his support and interest in my studies. I am indebted to Prof. Dr. Mehmet Tanyaş at the Department of International Logistics of the Okan University for his continuous support not only during this study but also through my whole academic life. I feel privileged to have met and worked with him. I want to thank all the supply chain professionals who contributed to this study by taking the time to complete the survey questionnaire. I especially thank (in alphabetical order) Reha Akşener, Dr. Muhammed Bamyacı, Aydan Bilgel, Osman Circi, Erdal Erkut, Taner Öztürk, Cem Sarıkaya, and Dr. Halefşan Sümen for taking part in the workshop and providing many valuable comments. I want to thank my employer, the Department of Industrial Engineering of the Istanbul Technical University, for giving me the opportunity to study in Berlin and the professors, colleagues, and personnel working there for supporting me in numerous ways. I thank my dear friend Dr. Yüksel Pögün-Zander for being there for me whenever I need her and for reading, editing, and commenting on my thesis. I owe a lot to my parents and my sister for their unconditional love, care, and support. I also want to thank my parents-in-law and my sister-in-law for their continuous support. Above all, I owe a great deal to my husband, Dr. Umut Asan, for his love, forbearance, support, and encouragement at all times. Berlin, 2009 Şeyda Serdar Asan TABLE OF CONTENTS Table of Contents .................................................................................................................i List of Figures ................................................................................................................iv List of Tables ................................................................................................................vi List of Boxes ..............................................................................................................viii List of Abbreviations..........................................................................................................ix CHAPTER 1. INTRODUCTION................................................................................... 1 1.1 Context of the study .............................................................................. 1 1.2 Purpose of the study.............................................................................. 4 1.3 Methodology of the study ..................................................................... 5 1.4 Significance of the study ....................................................................... 6 1.5 Organization of the study ..................................................................... 6 CHAPTER 2. DEALING WITH COMPLEXITY......................................................... 9 2.1 Definition of complexity........................................................................ 9 2.2 Characteristics of complex systems ................................................... 14 2.3 Measuring complexity......................................................................... 19 2.4 Ways to deal with complexity............................................................. 21 2.5 Summary and conclusions of Chapter 2 ........................................... 28 CHAPTER 3. SUPPLY CHAIN COMPLEXITY........................................................ 30 3.1 Characteristics of supply chain as a complex system....................... 31 3.2 Drivers of complexity in the supply chain......................................... 36 3.3 Dealing with complexity in the supply chain .................................... 38 3.4 Complexity measurement in the supply chain.................................. 42 3.5 A categorization of supply chain complexity research .................... 43 3.6 Summary and conclusions of Chapter 3 ........................................... 49 CHAPTER 4. STATE OF THE ART APPROACHES TO COMPLEXITY IN THE SUPPLY CHAIN .................................................................................. 52 4.1 A review of key supply chain management activities....................... 53 4.2 A review of supply chain management tools..................................... 57 4.3 A review of supply chain enabling technologies ............................... 59 4.4 Complexity management in the supply chain survey ...................... 63 Table of Contents ii 4.4.1 Research method ................................................................................... 63 4.4.2 Survey findings..................................................................................... 65 4.4.3 Discussion of the survey findings ......................................................... 74 4.5 Summary and conclusions of Chapter 4 ........................................... 75 CHAPTER 5. MANAGING COMPLEXITY IN THE SUPPLY CHAIN .................. 78 5.1 Supply chain complexity management framework.......................... 82 5.1.1 Supply chain structure........................................................................... 83 5.1.2 Supply chain flows................................................................................ 85 5.1.3 Supply chain decision-making .............................................................. 87 5.1.4 Putting it all together............................................................................. 91 5.2 A methodology based on Theory of Constraints’ Thinking Processes............................................................................................... 92 5.2.1 Stage 1: Expressing the problem situation ............................................ 95 5.2.2 Stage 2: Describing the system and its relevant elements..................... 96 5.2.3 Stage 3: Describing the current situation ............................................ 101 5.2.4 Stage 4: Determining and resolving the uncertainties/conflicts.......... 106 5.2.5 Stage 5: Defining desirable and feasible changes ............................... 111 5.2.6 Stage 6: Plan and take action............................................................... 116 5.2.7 An overview of the methodology........................................................ 122 5.2.8 The use of the methodology................................................................ 124 5.3 Summary and conclusions of Chapter 5 ......................................... 125 CHAPTER 6. ASSESSING THE QUALITY OF THE PROPOSED FRAMEWORK AND THE METHODOLOGY ........................................................... 126 6.1 A meta-analysis of real life cases...................................................... 127 6.1.1 Selection of the cases .......................................................................... 128 6.1.2 A systematic review of the selected cases........................................... 132 6.1.3 Interpretation of the findings............................................................... 132 6.2 Elicitation and analysis of expert opinions ..................................... 135 6.2.1 Selecting the experts............................................................................ 135 6.2.2 The workshop...................................................................................... 135 6.2.3 Results of the workshop ...................................................................... 138 6.3 Conclusion.......................................................................................... 139 6.3.1 Trustworthiness of the framework and the methodology.................... 139 6.3.2 Suggestions for future research related to research methodology....... 141 6.4 Summary and conclusions of Chapter 6 ......................................... 144 Table of Contents iii CHAPTER 7. CONCLUSION ................................................................................... 145 7.1 Summary and contributions............................................................. 145 7.2 Suggestions for future research ....................................................... 147 REFERENCES .............................................................................................................148
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