Strategic Production Networks Springer-Verlag Berlin Heidelberg GmbH
LiZheng Frank Possel-Dolken Strategic Production Networks With 210 Figures and 17 Tables, Springer
Professor Dr. Li Zheng Tsinghua University Department of Industrial Engineering Beijing 100084, P. R. China Dipl.-Ing. Frank Possel-Dolken Aachen University of Technology Laboratory for Machine Tools and Production Engineering 52056 Aachen, Germany ISBN 978-3-642-07734-0 DOI 10.1007/978-3-540-24812-5 ISBN 978-3-540-24812-5 (ebook) Library of Congress Cataloging-in-Publication Data applied for Die Deutsche Bibliothek - CIP-Einheitsaufnahme Zheng, Li: Strategic Production Networks: with '7 Tables / Li Zheng; Frank Possel-Dolken. Berlin; Heidelberg; New York; Barcelona; Hong Kong; London; Milan; Paris; Tokyo: Springer, 2002 This work is subject to copyright. AII rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permiued only under the provisions of the German Copyright Law of September 9, '965, in its current version, and permission for use must always be obtained from Springer-Verlag. Violations are liable for prosecution under the German Copyright Law. Springer-Verlag Berlin Heidelberg New York a member of BertelsmannSpringer Science + Business Media GmbH hup:/ /www.springer.de Springer-Verlag Berlin Heidelberg 2002 Sottcover reprint ofthe hardcover 1 st edition 2002 The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Cover design: Erich Kirchner, Heidelberg SPIN 10865127 42/2202-5 4 3 2 1 o - Printed on acid-free paper
Contents 1 Challenges for Today's Production Companies... 1 F. Possel-Doelken, L. Zheng 1.1 The Business Environrnent... l 1.2 A Shift in Paradigms... 3 1.3 Objectives... 5 1.4 References for Chapter 1... 5 2 Cooperation Between Production Companies... 7 F. Possel-Doelken, L. Zheng 2.1 Definition of Cooperation... 7 2.2 Cooperation Objectives... 8 2.3 Cooperation Types... 10 2.4 Contents of the Cooperation in Strategic Networks... 14 2.5 The Cycle of Cooperation... 18 2.5.1 The Phases of Cooperation... 19 2.5.2 Success Factors and Problems of Strategic Networks... 20 2.6 Cooperation Enabling Technologies... 23 2.6.1 Business Information Engineering... 23 2.6.2 Distributed Object Technology... 27 D. B. Tang 2.7 References for Chapter 2...42 3 Telecooperation... 44 3.1 Fundamentals of Telecooperation...44 R. Reichwald 3.2 Dimensions oftelecooperation...45 R. Reichwald, K. Moslein, H. Englberger 3.2.1 Enabler: Communication and Information Technology...46
VI Contents 3.2.2 Telework: Media-Supported Distributed Work Processes....47 3.2.3 Telemanagement: Media-Supported Distributed Coordination of Work Processes....48 3.2.4 Teleservices: Media-Supported Provision of Services....48 3.3 Strategies and Future Development Perspectives... 49 K. Moslein 3.4 Benefits of Telecooperation - Experiences in German Industry... 52 H. Englberger 3.4.1 TWIST: Telecooperation at the BMW AG... 53 3.4.2 POLIKOM: Telecooperation in the Government... 54 3.4.3 Long-term Competitiveness... 55 3.4.4 Dispersion of Locations... 56 3.4.5 A Look at the Future... 56 3.5 Groupware... 57 J. Schlichter, M. Koch 3.5.1 Introduction... 57 3.5.2 Groupware Classification... 58 3.5.3 Classification According to the 3C Model..... 62 3.5.4 Shared Context... 63 3.5.5 Groupware Architectures... 67 3.5.6 Conclusion... 70 3.6 References for Chapter 3... 71 4 Quality Management in Collaborative Projects... 75 T. Pfeifer, C. Theis, M. Rabartsch 4.1 Co-operative Basis - Developing a Co-operative Culture... 77 4.1.1 Motivate (Sensitize and Raise Awareness)... 77 4.1.2 Training... 80 4.1.3 Delegate Responsibility... 82 4.1.4 Characteristics of a Basis for Co-operation... 84
Contents VII 4.2 Co-operative Marketing - Working out Agreements... 85 4.2.1 Approaching Other Companies... 86 4.2.2 Definition Phase... 92 4.2.3 Harmonization... 98 4.2.4 Characteristics of Co-operation Marketing... 10 1 4.3 Co-operation Management - Organizing Joint Work... 102 4.3.1 Planning and Organizing (Self-Organization)... 103 4.3.2 Managing... 106 4.3.3 Communicating and Controlling... 107 4.3.4 Characteristics of Co-operation Management..... 108 4.4 TQM in Company Networks... 109 4.4.1 Self-Reinforcing Effects of the System... 109 4.4.2 Developing Corporate Networks... 111 4.5 TQM-Oriented Co-operation - Summary... 111 4.6 References for Chapter 4... 112 5 Cooperation in Product Development... 115 5.1 Telecooperation in Product Development... 115 H. Luczak, C. Schlick, D. Herbst 5.1.1 Introduction... 115 5.1.2 Telecooperation in Cooperative Product Design... 119 5.2 A Feature-Based Approach for Cooperative Product Development... 13 3 0. Thome, M. Wittmann 5.2.1 Introduction... 134 5.2.2 Feature Technology... 134 5.2.3 Tolerance Information System... 135 5.2.4 Reference Model for Usage of Distributed Tolerance Knowledge... 137 5.2.5 Tolerance Knowledge Base... 138
VIII Contents 5.2.6 Function-Related Design... 138 5.2.7 Enlarged Feature Approach... 140 5.2.8 Conclusion... 141 5.3 Product Data Exchange Technologies... 142 L. Tian 5.3.1 Product Data Exchange Standards - Introduction... 142 5.3.2 Fundamentals of the STEP Standard... 144 5.3.3 Implementation of STEP... 150 5.3.4 Typical Examples for the Application of STEP... 155 5.4 References for Chapter 5... 166 6 Cooperation in Operations Planning... 171 6.1 Cooperation With Tool and Fixture Suppliers... 171 W. Eversheim, M. Westekemper, F. Spennemann 6.1.1 Introduction... 171 6.1.2 Development of the Tool Making Industry... 173 6.1.3 The New Role of the Tool Maker.... 178 6.1.4 Tool Makers as System Suppliers... 184 6.1.5 Win-Win-Situation Through Cooperation... 187 6.1.6 Call for Action in the Tool Making Industry... 192 6.1.7 Vision... 197 6.1.8 Conclusion... 198 6.2 CIMSOURCE... 199 R. Grosse Wienker 6.2.1 Basic Idea and Story... 199 6.2.2 Contents ofcimsource Global Tool Information... 202 6.2.3 How CI MSOU RCE Supports Operation Planning... 206 6.3 Web-based Process Planning for Turning and Distributed Resources... 208 L. Zheng
Contents IX 6.3.1 Introduction... 208 6.3.2 Overview of the System... 209 6.3.3 System Information Flow... 215 6.3.4 Machining Parameter Selection for Turning Processes... 215 6.3.5 Case Study... 218 6.3.6 Conclusion... 220 6.3.7 Acknowledgements... 220 6.4 References for Chapter 6... 220 7 Supply Chain Management... 223 7.1 Actual Problems in the Supply Chain... 223 F. Possel-Doelken, L. Zheng 7.1.1 Current Rationalization Objectives... 223 7.1.2 Weather Prediction and Logistics... 225 7.1.3 The Lack in Decision-Support... 227 7.2 Objectives and Concepts of Supply Chain Management... 228 F. Possel-Doelken, L. Zheng 7.2.1 What is Supply Chain Management... 228 7.2.2 Targets of Supply Chain Management... 229 7.2.3 Logistical Concepts of Supply Chain Management..... 232 7.2.4 Technologies for Supply Chain Management..... 234 7.2.5 Strategic Production Networks... 237 7.3 Reference Modeling... 238 F. Possel-Doelken, L. Zheng 7.4 Advanced Logistic Partnership-Model... 240 P. Schonsleben 7.4.1 Overview... 240 7.4.2 Choosing the Strategy of Cooperation... 241 7.4.3 Strategic Level: Building Trust and Establishing Principal Legal Relationships... 242
X Contents 7.4.4 Technical-Commercial Level: Developing and Introducing Products and Processes... 244 7.4.5 Operational Level: Cooperative Customer Order Planning and Execution... 246 7.4.6 An Example of Practical Application... 247 7.5 PRO-Net Reference Model for the Technical Order Processing... 250 F. Possel-Doelken, L. Zheng 7.5.1 Objectives of the PRO-Net Reference Model...... 250 7.5.2 The PRO-Net Structure... 258 7.5.3 The PRO-Net Reference Production Network... 259 7.5.4 Cooperation Management... 263 7.5.5 Integrated Planning Levels... 268 7.5.6 Monitoring and Feedback Loops... 271 7.5.7 The Cooperative Supply... 278 7.5.8 Subcontracting... 284 7.5.9 Distribution... 285 7.5.10 Vendor Managed Inventory and CPFR... 286 7.5.11 The Sample Processing... 289 7.5.12 Receipt of Goods... 291 7.5.13 Complaint Management..... 293 7.5.14 Further Developments... 293 7.6 Supply Chain Operations Reference Model... 294 F. Possel-Doelken, L. Zheng 7.7 Supply Chain Management in Plant Construction... 299 R. Wojanowski, M. Schenk 7.7.1 SCM in Plant Construction... 299 7.7.2 Specific Requirements in Plant Construction... 303 7.7.3 SCM Potentials in Plant Construction... 305 7.7.4 Main Task: Cooperation... 308
Contents XI 7.7.5 Main Task: Process Control...... 312 7.7.6 Benefit Potentials Through Integrated SCM in Plant Construction... 318 7.8 Supply Chain Management Software - State of the art... 320 D. Palm, W Sihn 7.8.1 Prospects and Benefits Through the use of SCM Software... 321 7.8.2 Why are PPC and ERP Systems not Sufficient?... 323 7.8.3 Spectrum of Tasks of Supply Chain Management Software... 324 7.8.4 Supply Chain Planning... 325 7.8.5 Available-to-Promise... 333 7.8.6 Supply Chain Execution... 333 7.8.7 Supporting Tasks... 336 7.8.8 Integration of Transaction and SCM Planning Systems... 337 7.8.9 SCM Software Market... 338 7.8.10 Selection and Introduction of SCM Software... 342 7.9 Process-Oriented Supply Chain Reengineering... 344 K. Erzen, M. Klaschka 7.9.1 Competition Situation of European Textile Production Networks... 345 7.9.2 Objectives... 348 7.9.3 Project Management... 350 7.9.4 Project Realization... 352 7.9.5 Results... 357 7.9.6 Conclusion... 360 7.10 References for Chapter 7... 361 8 Management of Variable Production Networks... 368 H.-P. Wiendahl, S. Lutz 8.1 Introduction... 368 8.2 Production Networks... 369
XII Contents 8.3 Interfaces Within a Production Network... 370 8.4 Communication in a Production Network... 371 8.5 Types of Subcontracting... 373 8.5.1 Classic Subcontracting... 373 8.5.2 Stock-on-Hand Curves... 374 8.5.3 Capacity Driven Subcontracting... 376 8.5.4 Technology Driven Subcontracting... 377 8.6 Controlling and Monitoring Requirements in Networks... 378 8.7 Applications of the Network Control... 380 8.7.1 The Case of Capacity-Driven Subcontracting... 380 8.7.2 The Case ofa Classic Subcontracting... 384 8.8 Constraints and Rules... 387 8.9 Conclusion... 387 8.10 References for Chapter 8... 388 9 Mass Customization... 389 F. Piller, R. Reichwald 9.1 What is Mass Customization?... 389 9.2 The Role ofinformation for Mass Customization... 393 9.3 Mass Customization and Electronic Commerce... 395 9.4 Empirical Findings... 396 9.5 The Information Cycle of Mass Customization... 398 9.6 Marketing and Configuration Networks for Mass Customization... 40 I 9.6.1 Retail and Configuration Channels....401 9.6.2 Intermediaries in Mass Customization Concepts....402 9.6.3 Systematization of Broker Networks for Mass Customization... 407 9.7 Production Networks for Mass Customization....409 9.7.1 Implementation of Production Networks....409
Contents XIII 9.7.2 New Requirements for PPC Systems....413 9.7.3 Design ofinformation and Communication Flows....414 9.8 Conclusion....416 9.9 References for Chapter 9....417 10 Virtual Factories and Enterprises... 422 G. Schuh, T Friedli 10.1 What is a Virtual Factory....422 10.1.1 Definition....422 10.1.2 Background... 423 10.1.3 Concept....425 10.1.4 The Dynamic Network....428 10.1.5 The Virtual Factory - From Capacity Exchange to Benchmarking....429 10.2 Establishing Virtual Factories....430 10.2.1 Trust as Condition....430 10.2.2 Trustbuilding Between Organizations....430 10.2.3 Conclusion for Establishing Virtual Factories....430 10.3 Running Virtual Factories....431 10.3.1 Needed Management Capacities....431 10.3.2 Permanent Improvement and Innovation....432 10.4 The Virtual Factory Euregio Bodensee....432 10.4.1 Experiences Made so far....433 10.4.2 The Future of the Virtual Factory - Towards Professionalism....434 10.5 Summary... 438 10.6 KIM-BaWii - Virtual Marketplace for SME Co-operation....438 D. Palm, W Sihn 10.6.1 The Project: KIM-Ba Wii....439 10.6.2 Virtual Marketplace....440
XIV Contents 10.6.3 Elements and Concept of the Virtual Marketplace....442 10.7 References for Chapter 10....445 11 Cooperation Networks for Industrial Services....447 C. Gill, V. Liestmann 11.1 Current Situation of Small and Medium Enterprises....447 11.1.1 Characteristics of Small and Medium Enterprises....448 11.1.2 Basic Conditions in the Business Environment......449 11.1.3 Strategies of Small and Medium Enterprises....449 11.1.4 Limited Resources of Small and Medium Enterprises....449 11.2 Industrial Services....451 11.2.1 Definition and Classification....451 11.2.2 Types ofindustrial Services....451 11.2.3 Targets of Providing Industrial Services....453 11.2.4 Provision of Industrial Services by Small and Medium Enterprises....454 11.2.5 Developments in Germany....455 11.3 Features of Cooperation in Industrial Services....456 11.3.1 Cooperation Forms in Industrial Services....456 11.4 Requirements on the Organization of Co-operations in Industrial Services... 458 11.4.1 Evaluation-Fields for Enterprises....458 11.4.2 Organizational Fields for Cooperation....458 11.4.3 Requirements on Cooperation ofindustrial Services....460 11.5 References for Chapter 11....463 12 Cooperation in Knowledge Management....468 K. Henning, R. Oertel, C. Henrichs 12.1 Introduction....468 12.1.1 The need for Demand-Orientated Innovation in an Increasingly Complex Global Market.......469
Contents XV 12.1.2 The Strategy of SENEKA: Cooperation for Utilizing Knowledge in Line With Demand....471 12.2 Model and Hypotheses....472 12.3 How Does SENEKA Work in Practice?....474 12.3.1 Virtual Institute: Organizational Development in Networks....475 12.3.2 Virtual Institute: Personal Development for Network Participants....476 12.3.3 Virtual Institute: Knowledge Management.......476 12.3.4 Virtual Institute: Innovation Management......477 12.3.5 The Virtual Platform SENEKA....477 12.3.6 Project Activities Empirically Reassessed....478 12.4 Conclusion....4 78 12.4.1 The Current Project Consortium....479 12.5 References for Chapter 12....480 13 Abbreviations... 481 14 Authors... 484