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The Meeting of Configurable Product Families and Sales- Delivery Process

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The Meeting of Configurable Product Families and Sales- Delivery Process Julkaisu 712 Publication 712 Antti Pulkkinen Product Configuration in Projecting Company: The Meeting of Configurable Product Families and Sales- Delivery Process Tampere 2007 Tampereen teknillinen yliopisto. Julkaisu 712 Tampere University of Technology. Publication 712 Antti Pulkkinen Product Configuration in Projecting Company: The Meeting of Configurable Product Families and Sales- Delivery Process Thesis for the degree of Doctor of Technology to be presented with due permission for public examination and criticism in Festia Building, Auditorium Pieni Sali 1, at Tampere University of Technology, on the 11th of December 2007, at 12 noon. Tampereen teknillinen yliopisto - Tampere University of Technology Tampere 2007 ISBN 978-952-15-1897-3 (printed) ISBN 978-952-15-2048-8 (PDF) ISSN 1459-2045 “Always design a thing by considering it in its next larger context – a chair in a room, a room in a house, a house in an environment, an environment in a city plan.” -Eliel Saarinen ii Abstract The work presented in this dissertation is a qualitative research in the field of engineering design. The applied research method involves case studies and interviews in the industry. The data collection methods are briefly explained. A literature review is presented for the purpose of crafting the method of analysis for the collected data. The context of the research is a projecting company which carries out sales-delivery processes with a project-based business paradigm. The concept of projecting is defined along with the engineering design and product development literature. The emphasis is on the project management situations as well as on the propagation of the engineering change. It is argued that the propagation of changes causes the project management situation to evolve from one stage to another. Moreover, with product configuration the evolution of management situation can be controlled. An engineering design process is reviewed from the viewpoint of product structuring. The problems related to the development of standard, fixed products are reviewed and related to projecting. It is argued that the standardisation of product structures and architectures as a configurable product family can alleviate the problems related to the evolution of project management situation. The different stages of product development are reviewed. Product configuration is defined and examined from both the design knowledge and the reuse point of view. Product configuration is presented as an option for product design in projecting. The sales-delivery processes are studied from the viewpoint of customization in process, product standardisation, as well as production. It is argued that the customization as well as standardisation of product design affects the sales delivery processes which constitute the state of a sales-delivery process. It is argued that the development of configurable product families is a means of transforming the state of the sales-delivery processes. Moreover, the scope of transformation, the functions and the organisations of sales-delivery project, are related to the means of transformation, the configurable product family. Applying the model of integrated product development is suggested. The direct results of the interviews and the case studies are presented. In addition, an analysis of the collected material is presented. The analysis is conducted according to the synthesis of the literature review. It is pointed out that the changes of product design often have pervasive dispositional effects on the project activities. Thus, there is reason to believe that the first argument is valid. The application of configurable product families has had positive effects on the sales-delivery processes of projecting companies, such as sufficient engineering resources and shortened lead times. These are implications of the second argument, which can be regarded as valid. Both the interviews and the cases are related to the scope, means, and objectives of the development projects. The relations between the scope of the development project and its objectives are acknowledged. Also relations between the scope and the characteristics of the development project are examined. The cases and the interviews as a whole imply that the application of configurable product families in a projecting company is a means of transforming the focus from sales-delivery projects to systemic customization. This, however, requires the alingment of the means with the scope. iii Acknowledgements This report combines the pieces of knowledge derived from practical experiences. My experience is based on participation in a set of development projects in industrial companies as well as interviewing people who have expertise in the field. The set of projects started at the end of the previous millennium, with the Design for Configuration research project (DFC, 1997-1999), and four industrial companies with their own development projects. Verso-project (2000-2003) concentrated on the networking of companies participating in power plant delivery projects. Another research project, Conceptual Design for Manufacturing and Assembly (C_DFMA, 2005- 2007), had a similar structure with eight industrial development projects. All three projects were funded by Tekes, the Finnish Funding Agency for Technology and Innovation. In between the two research projects, I have had an opportunity to participate in the instruction of seven M.Sc. candidates who wrote their theses for industrial companies. Three of the case studies derive from such a connection. The cases and interviews are shaded in Table 1. The contacts with people in the industry have been invaluable for my research. I am deeply grateful to the people in the companies for sharing a part of their time for the benefit of this research. The list of companies that have supported this research is presented in Table 1. Table 1. The companies that have supported this research DFC-project Intermediate projects C_DFMA-project (1997-1999) (2000-2006) (2005-2007) Sandvik Tamrock (now Sandvik Mining Verso-project ABB and Construction) (2000-2003) Kaso Kvaerner Pulping Elcoteq (Metso Power) KCI Konecranes (Konecranes) YIT Power Konecranes (YIT Industria) Tunturi (part of Accel Group) Fortum Engineering Nokia Mobile Phones (Metso Power) Datex Ohmeda (part of General Elec- ABB Nokia Siemens Net- tric Healthcare) works Neles-Jamesbury (part of Metso Metso Automation Metso Minerals Automation) Ponsse Wärtsilä Perlos Rocla Fastems (2001) Rolls Royce Sisu Terminal Systems (Kalmar Indus- Metso Paper Wärtsilä tries, part of Cargotech Corporation) (2003-2004) Valtra (part of Acgo Corporate) Profile Vehicles (2005-2006) Wärtsilä NSD (Wärtsilä) I am also obliged to Professor Asko Riitahuhta, who has not only shared his knowledge and contacts with his research group, but also supported and encouraged me in the progress of the research from DFC to C_DFMA. A number of researchers have had an influence on the research reported here. In the Workshop of Product Structuring and Modularisation 2003, in Copenhagen, Professor Niels Henrik Mortensen advised me to "just carry another little stone on the mountain". In the International Conference on Engineering Design 2007, in Paris, Ulf Harlou and Petri Huhtala encouraged me to push through iv with my ideas with such sentences as "I see that there is a contribution..." These small words have had an effect that is more valuable than one might conceive at first glance. I also appreciate the efforts of Juha Tiihonen, Timo Lehtonen, Tero Juuti, Kati Sarinko, and Heli Laurikkala as well as Davor Pavlic and Mikko Vanhatalo in research projects where the situation has varied from complex to almost chaotic. Also, comments from the group of industrial Ph.D. students have been important. In particular, discussions with Seppo Suistoranta, Hannu Oja, and Niko Salonen have deepened my insight on the practical problems in engineering design. I am grateful to Rea-Maria Lehtonen for the proofreading of this dissertation. However, work and studies would be just too hard to bear without friends and family, who, in the words of Mohammed Nadir, give the "strength of life". I appreciate his advice and company in charging the batteries. My band mates from The Generations and The Harkko have provided me with opportunities to step out of the continuum of everyday chores. Thanks, Markus et al. “Tie them sticks in a bundle and try to break that." Course they couldn't. Then I'd say, "That bundle... that's family"; quoting Alvin Straight. My wife has been indispensable in innumerable ways. Thank you, Inka! Also, warm thanks to my parents and parents-in-law for their support. I dedicate this work to my son Eelis, who has shown me the best example in the resilient steps of research, which generate the pure joy of success. Kangasala, November 2007 Antti Pulkkinen v vi Table of Contents ABSTRACT ........................................................................... III ACKNOWLEDGEMENTS ........................................................ IV TABLE OF CONTENTS .......................................................... VII LIST OF FIGURES ................................................................. IX LIST OF TABLES .................................................................. XI LIST OF ABBREVIATIONS ..................................................... XIII INTRODUCTION .................................................................... 1 Development at large......................................................................
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