Early involvement in the design chain—a case study from the computer industry

This work presents a case study of how a design chain, with more than three tiers of organisations (customer, manufacturer, and supplier), can involve its members in the early stages of the design and development process to meet their needs more effectively. A vertical design chain model, consisting of strategy, process and information levels, is adopted to elucidate how a computer company can provide for different customers and use various suppliers to create synergy within the design chain. The results of this study demonstrate that the re-engineering of cross organisation product design flow, product data management software applications and the integration of information from various parties are critical to the early involvement in a vertical design chain. Based on this case study, the proposed early involvement model can shorten the time taken to develop new products and considerably reduce the number of engineering changes for various manufacturers.     

New product development and the effect of supplier involvement

This study investigates the problem of new product development (NPD) under supplier involvement (SI) program in a supply chain comprising a single supplier and a single buyer. The buyer, the Stackelberg leader in the supply chain, configures the design quality of the product and determines the extent of SI – the degree to which the supplier is involved in the NPD project – in order to utilize the complementary capability of the supplier. The supplier in charge of production determines the level of conformance quality to design specifications. Using the principal-agent paradigm, we propose an analytical framework that investigates the role of the SI program in the NPD project, incorporating essential factors such as the R&D cost, the transactional inefficiency, the production cost, and the transfer payment. We provide rich managerial insights into the decentralized NPD practice by analyzing the equilibrium behaviors of major decision variables (design quality, conformance quality and SI extent) with respect to internal and external environmental conditions.     

Early supplier involvement in the design process: lessons from the electronics industry

The movement of activities earlier in the product development process, necessitates a re-examination of the total supply network. Supply chain literature has traditionally examined procurement and value-adding activities, without explicitly defining product development as part of these. The trend towards outsourcing design activities is bringing recognition for this process as part of the total supply network. The objective of this paper is to determine the degree of early supplier involvement (ESI) that exists between a multinational electronics company and its key suppliers, in terms of depth of integration, information exchange and buyer–supplier relationships. The paper provides insights into the strategic factors that affect the dynamics of the ESI process. Such insights are valuable in terms of gaining a greater understanding of how the ESI process is managed and determining the barriers to effective supplier integration. The research indicates that there are considerable impediments for those participants responsible for establishing and managing the implementation of ESI. A number of strategic insights are identified that explain the existence of the impediments to the ESI process. Finally, based upon the findings a number of lessons are highlighted for organisations considering the adoption of the ESI process.     

A Risk Analysis Model in Concurrent Engineering Product Development

Concurrent engineering has been widely accepted as a viable strategy for companies to reduce time to market and achieve overall cost savings. This article analyzes various risks and challenges in product development under the concurrent engineering environment. A three‐dimensional early warning approach for product development risk management is proposed by integrating graphical evaluation and review technique (GERT) and failure modes and effects analysis (FMEA). Simulation models are created to solve our proposed concurrent engineering product development risk management model. Solutions lead to identification of key risk controlling points. This article demonstrates the value of our approach to risk analysis as a means to monitor various risks typical in the manufacturing sector. This article has three main contributions. First, we establish a conceptual framework to classify various risks in concurrent engineering (CE) product development (PD). Second, we propose use of existing quantitative approaches for PD risk analysis purposes: GERT, FMEA, and product database management (PDM). Based on quantitative tools, we create our approach for risk management of CE PD and discuss solutions of the models. Third, we demonstrate the value of applying our approach using data from a typical Chinese motor company.     

A Structural Equation Model of New Product Design and Development*

This research uses structural equation modeling to analyze the effects of supplier assessment, Just‐In‐Time, and quality management strategies on new product design and development. A survey of senior managers who are members of the American Production and Inventory Control Society in the United States was used to test the relationships between the constructs in the model. In general, the survey results supported the proposed structural equation model. The data showed that supplier assessment and Just‐In‐Time strategies were correlated and affected the quality management strategy used, which in turn influenced the new product design and development strategy. The data also showed that the Just‐In‐Time strategy directly influenced the new product design and development strategy.     

Internal and External Integration for Product Development: The Contingency Effects of Uncertainty,Equivocality, and Platform Strategy

Effective product development requires firms to unify internal and external participants. As companies attempt to create this integrated environment, two important questions emerge. Does a high level of internal integration lead to a higher level of external integration? In the context of product development, this study considers whether internal integration in the form of concurrent engineering practices affects the level of external integration as manifested by customer integration, supplier product integration, and supplier process integration. External integration, in turn, may influence competitive capabilities, namely product innovation performance and quality performance. Second, using contingency theory, do certain contextual variables moderate the linkages between integration strategy (external and internal) and performance? Specifically, this study considers whether uncertainty, equivocality, and platform development strategy change the relationships among internal integration, external integration, and competitive capabilities. Data collected from 244 manufacturing firms across several industries were used to test these research questions. The results indicate that both internal and external integration positively influence product innovation and quality and ultimately, profitability. With respect to contingency effects, the results indicate that equivocality moderates the relationships between integration and performance.     

Supplier involvement in product development in the electronics industry: A case study

The movement of activities earlier in the product development process requires a re-examination of the total supply network. The objective of this paper is to determine the degree of early supplier involvement (ESI) that exists between a multinational electronics company and its key suppliers, in terms of depth of integration, information exchange and buyer–supplier relationships. The paper provides insights into the strategic factors that affect the dynamics of the ESI process. The research indicates that there are considerable impediments for those participants responsible for establishing and managing the implementation of ESI. A number of strategic insights are identified that explain the existence of the impediments to the ESI process. Finally, based upon the findings a number of lessons are highlighted for organisations considering the adoption of the ESI process.     

An integrated functional representation of concurrent engineering

A time-based competitive strategy is a driving force for enterprises that are striving to be competitive on a global basis. One of the methods to help in the time compression of the product development life cycle is concurrent engineering. Concurrent engineering is not only an approach that is used by the engineering function of the organization, but it is also one that crosses organizational boundaries. In this article an integrated functional model of the concurrent engineering process and its relationship with the product development life cycle is presented. A functional comparison to the traditional engineering approach for product development is also provided.     

基于供应商参与新产品开发的供应商选择影响因素分析及实证研究

供应商参与新产品开发(Supplier Involvement in New Product Development,SINPD)已受到越来越多国内外企业的关注,选择合适的供应商参与新产品开发成为企业实施SINPD的关键。以我国制造企业为研究对象,通过对国外相关文献的分析提炼出供应商选择的影响因素,据此设计了问卷量表,利用调研数据进行统计分析验证。研究表明,供应商技术能力、供应商的信誉及企业特征、供应商的合作经历、双方合作兼容性、供应商情景及合作的意愿是我国制造企业选择供应商的关键影响因素。     

Limits to Concurrency*

In the global race to bring new products to market, many firms have adopted concurrent engineering as a technique to shrink development lead time. Due to the many concurrent engineering success stories in the business and engineering literature, a common misconception has grown that more concurrency is always better. The major contribution of this paper is a rigorous demonstration that limits to concurrency exist even in the simplified situation in which concurrency is modeled as the number of design modules to be executed in parallel. As complexities such as communication linkages between modules are layered onto our basic model, we show that the expected project completion time is minimized at a finite number of modules, a number that decreases with increasing problem complexity. In general, the more complex the project, the stricter the limits to concurrency. This strongly suggests that project managers should be cognizant of the potentially adverse effects of pushing concurrency too far.     

跨企业组织协同产品开发中供应商早期参与策略研究

在跨企业组织的协同产品开发中,供应商的参与时间和设计活动间的信息交流是影响整个产品开发时间和供应商开发成本的重要因素之一。基于对设计活动的技术创新程度和下游制造商信息对上游供应商的重要程度,扩展了知识累积函数和设计返工函数。针对供应商的参与时间和信息交流次数,建立了供应商参与协同产品开发模型,通过构造考虑产品开发时间和供应商开发成本权衡的全局收益变量,证明了全局收益极大值的存在性。在此基础上,分别给出了供应商最优参与时间和最优的信息交流次数的计算公式以及供应商参与协同产品开发策略选择的判定条件。最后通过实例验证了该结论的适用性。     

Critical success factors in managing modular production design: Six company case studies in Hong Kong, China, and Singapore

Many researchers have explored the advantages of modular product design, its design methods and its effects on product performance. Modular design is, for example, required for product platform, mass customization and postponement in order to achieve greater product variety and differentiation. However, a few empirical studies explicitly examine how to coordinate modular product design in a managerial way. This paper addresses it by conducting multiple case studies with six companies which have successfully adopted modular product design for five years. Seven critical factors are explored in the management of modular product design. These are pre-defined product advantage, selectively used design rules, module definition, system integration, technological newness, internal communication, and supplier and customer involvement. While most of the literature studies the technical dimension of modular design within a firm, this study focuses on the managerial side across the supply chain. It gives new insights on how to manage modular product design and proposes future research opportunities.     

A modelling approach for production costing and continuous improvement of manufacturing processes

It is shown how production management constraints can be taken into account as early as the design stage of the product. It is then shown that the indication of physical and economic performances is a means to obtain integration and to continually improve the manufacturing processes. To perform continuous and efficient evaluation of physical and economic performances, the concept of activity is introduced, now acknowledged as a basic concept of cost management systems. A modelling approach is then proposed to allow each member of the design team, in a concurrent engineering context, to perform activity based modelling and estimations with simulation. After describing the set of possible situations in which this approach can be used, an application case is presented concerning a French firm, and the advantages and disadvantages of the approach are discussed.     

Toward a Typology of Buyer–Supplier Relationships: A Study of the Computer Industry*

Buyer–supplier relationship typologies are useful analytical tools for purchasing managers in managing exchange relationships with suppliers and monitoring their purchasing portfolios. Existing buyer–supplier relationship typologies are mainly focused on either relational contents or power‐dependence and have limited empirical support for their performance implications. In this study, we developed an alternative buyer–supplier relationship typology that integrates both relational content and power‐dependence dimensions, resulting in four generic relationship types: market, power, autonomous‐link, and constrained‐link relationships. We then performed a longitudinal exploratory investigation of eight leading firms in the U.S. computer industry to explore the performance implications of the typology, using a combinatorial qualitative approach that leverages the strengths of case study research, content analysis, and quasi‐experimental design. The results suggest three theoretical propositions. First, the association between the type of buyer–supplier relationships and buyer firm performance varies such that constrained‐link relationships are superior in terms of operational efficiency while autonomous‐link relationships are superior in terms of product innovation. Second, the positive association between buyer–supplier relational contents (i.e., relationalism) and buyer firm operational efficiency is strengthened as the suppliers' dependence on the buyer firm increases. And finally, the positive association between buyer–supplier relationalism and buyer firm product innovation is weakened as the suppliers' dependence on the buyer firm increases.     

Concurrent consideration of product design,process planning and production planning activities

In manufacturing engineering, product design, process planning and production planning activities are often considered independently. However, in order to effectively respond to changes in business situations, such as changes in demand forecast, product mix and technology, it is desirable to consider them concurrently. For this purpose, a large-scale linear programming model has been developed. The model considers minimization of the sum of processing cost, late shipment cost and inventory holding cost as the objective, and concurrently selects product designs, and generates process plans and production plans. The number of columns in the formulation can be large and, hence, an efficient column generation scheme is developed to solve the model. The model and solution procedure are illustrated with examples.     

Order Release in Automated Manufacturing Systems

Order release occurs when orders are released to the shop floor for processing. An order release mechanism (ORM) selectively releases orders to improve shop management and performance. This paper focuses on the question of how to select and develop better ORMs, providing guidelines for practice. We develop a number of propositions on how an ORM should be established and the impact of implementing an ORM. To test the validity of these propositions, we consider three real different automated manufacturing systems. For each system, ORMs are developed and implemented in simulation models. Analysis of the experimental results suggests that some propositions are true under all situations, whereas the degree of validity of others is dependent on variables like system type, and the levels of other design variables. We conjecture that all the propositions can be accepted when the volume of production is high. We use the analysis and the propositions to generate guidelines for practice and areas for future research.     

CLOCKSPEED‐BASED STRATEGIES FOR SUPPLY CHAIN DESIGN1

This paper discusses a framework for strategic supply chain design that rests on an assortment of conceptual approaches. These approaches include benchmarking fast‐evolving industries to posit principles of supply chain dynamics and integrating supply chain design into the concurrent processes of product and manufacturing system design. These approaches yield insights into sourcing strategy as well as implementation of concurrent engineering.     

Competitive and Collaborative Quality and Warranty Management in Supply Chains

Product quality and product warranty coverage are two important and closely related operational decisions. A longer warranty protection period can boost sales, but it may also result in dramatically increased warranty cost, if product quality is poor. To investigate how these two decisions interact with each other and influence supply chain performance, we develop a single‐period model with a supplier that provides a product to an original equipment manufacturer, which in turn sells it to customers. Customer demand is random and affected by the length of the product warranty period. Warranty costs are incurred by both the supplier and the manufacturer. We analyze two different scenarios based on which party sets the warranty period: manufacturer warranty and supplier warranty. Product quality is controlled by the supplier, and the manufacturer determines the ordering quantity. We analyze these decentralized systems and provide the structural properties of the equilibrium strategies. We also compare the results of centralized and decentralized systems and identify the conditions under which one system provides a longer warranty and better product quality than the other. Our numerical study further shows that, in decentralized settings, when the warranty period is determined by the firm sharing the larger proportion of total warranty costs, the supply chain can achieve greater system‐wide profit. Both parties can therefore benefit from properly delegating the warranty decision and sharing the resulting additional profit. We further design a supplier‐development and buy‐back contract for coordinating decentralized supply chains. Several extensions are also discussed.     

工艺设计质量信息不对称环境下质量激励合同设计

工艺设计质量决定了产品可制造性，从而对产品质量产生重要影响。在生产外包环境下，不仅供应商的质量努力难以合同化，而且工艺设计质量可能是设计者的私人信息，因此在供应商和制造商之间往往是不对称的，从而为质量激励合同设计带来挑战。本文考虑一个制造商和一个供应商构成的两级供应链。制造商可能自己设计产品，然后将生产外包给供应商，也可能将设计和生产都外包给供应商。本文分析了在这两种外包策略下，制造商的质量激励合同设计。研究发现：1）当工艺设计质量是对称信息时，制造商可以通过质量合同设计实现全局最优质量和利润；2）当工艺设计质量是制造商的私人信息时，工艺设计质量高的制造商可以通过降低对供应商的质量惩罚强度以及增加采购价格来传递工艺设计质量的信号；3）当工艺设计质量是供应商的私人信息时，制造商可以通过质量合同菜单来甄别工艺设计质量信息。与工艺设计质量是对称信息时的均衡合同相比，在针对低工艺设计水平供应商的合同中，制造商降低质量惩罚强度和采购价格；在针对高工艺设计水平供应商的合同中，质量惩罚强度不变，但采购价格提高。