Jens Arnoscht

Integrative Production Technology for High-wage Countries

Manufacturing companies in high-wage countries are increasingly set under pressure in international competition due the lower production costs in low-wage countries. In order to counteract this development, many manufacturing companies respond to this issue by relocating their production facilities. Due to industrial production’s high dependence on other sectors such as the services sector, this trend threatens Europe’s medium and long term prosperity since outsourcing generally leads to subsequent relocation of services as well as of research and development activities (Lau 2005). With over 40% of German employees assigned to the manufacturing sector, production plays a key role in the national economy of Germany. Consequently, relocation of production poses huge risks for the country’s future economic development (Statistisches Bundesamt 2010).

Integrative Produktionstechnik für Hochlohnländer

Produzierende Unternehmen in Hochlohnlandern werden im internationalen Verdrangungswettbewerb immer starker durch die augenscheinlich im relativen Vergleich niedrigeren Produktionskosten in Niedriglohnlandern unter Druck gesetzt. Um dem entgegenzuwirken, reagiert eine grose Anzahl produzierender Unternehmen mit einer Verlagerung der Produktionsstatten. Auf Grund der starken Abhangigkeit weiterer Wirtschaftsbereiche (wie beispielsweise der Dienstleistungsbranche) von der industriellen Produktion, gefahrdet dieser Trend mittel- und langfristig den Wohlstand in Europa. (Lau 2005) Produktionsverlagerungen fuhren in der Regel auch zu nachfolgenden Verlagerungen von Dienstleistungs-, aber auch von Forschungs- und Entwicklungstatigkeiten. Da uber 40 % der sozialversicherungspflichtigen Erwerbstatigen in Deutschland dem produzierenden Gewerbe zugerechnet werden, nimmt die Produktion eine Schlusselrolle ein und ihre Abwanderung birgt immense Risiken fur die Entwicklung der Volkswirtschaft des Landes. (Statistisches Bundesamt 2010)

A generic model to handle complexity in collaborative networks

The importance of joining collaborations and maintaining relationships has significantly increased for industrial companies due to the globalisation of markets and the ongoing specialisation of companies. Consequently, adjustments in organizational structures are required by companies to fit the characteristics of industrial collaborations. With this, the complexity of collaborations in highly dynamic environments is increasing but often underestimated. This research is based on an EU founded project with the main goal to enlarge the knowledge of complexity in collaborative networks. In this paper we show the results of a questionnaire based survey identifying problems arising in such collaborative networks. Furthermore we link these problems to different system characteristics (e.g. network structure, trust, degree of commitment, coordination, change, etc.) and show how the problems and system characteristics influence each other based on case studies in two different collaborative networks. The research results in a generic model for complexity (GeMoC) in collaboration networks which is based on Beers viable system model and identifies white spots in the existing complexity research literature.

Assessment of the scale-scope dilemma in production systems: an integrative approach

Companies in high wage countries are increasingly confronted with the challenge of optimizing economies of scope and economies of scale simultaneously to succeed on a global market place. An integrated assessment of production systems facing this challenge is essential to evaluate the actual state of a company and to provide a basis for drawing the right conclusions to reconfigure production systems successfully. In this paper an integrated model for measuring economies of scope as well as economies of scale is introduced, defining the fundamental domains of a production system. The major objectives resulting from the overall scale-scope dilemma are broken down for each domain and the main dimensions for an assessment of each domain are defined. A new measure named Degree of Efficiency is defined, quantifying the fulfillment of the opposing objectives in each domain and hence, the contribution to an overall resolution of the scale-scope dilemma.

Contribution of Body Lightweight Design to the Environmental Impact of Electric Vehicles

In todays society the continuously increasing consumption of raw materials and the associated impacts on the ecosystem tend to be a frequently discussed topic. Especially automobile companies are faced to develop new driving concepts due to the emerging energy turnaround. Usually the components of the conventional drive are replaced by an electric engine including the required energy storage. Without structural changes regarding the chassis this procedure causes an increase in the vehicle ́s weight (Conversion Design). Therefore a new approach is to integrate the battery as a load-bearing member in the vehicle structure and additionally use a weight-optimized multi-material design of the body (Purpose Design). By savings of 25% of the weight of a compact-class vehicle body, a resource-saving and energy-efficient design of the entire vehicle can be achieved. Certainly the innovative multi-material construction contributes significantly to reduce the total energy consumption of the vehicle during the use phase. Based on a Lifecycle-Assessment (LCA) the environmental sustainability of the Purpose Design will be evaluated and compared to the approach of the Conversion Design. In addition to the weight savings of the multi-material body secondary weight reductions regarding the energy storage will be taken into account. The aim is to assess the ecological advantages of the lightweight solution throughout the entire product life cycle comprising the extraction of raw materials, production of the components, use of the product and end of life including the recycling of components. However, these investigations will be carried out for the modified chassis and the lightweight constructed multi-material body. Hence, the processes of the individual life cycle phases will be collected, inventorial analysis carried out and impact assessments performed. According to the LCA it will be tested, if the additional expenses in raw material extraction, production and recycling of the lightweight body justify the expected ecological advantage in the use phase. A final overall analysis will provide information on the actual efficiency and sustainability of the Purpose Design. Due to the parallel creation of the LCA data during the development process the LCA results furthermore serve to detect and monitor significant shortcomings on component and assembly level.

Increasing Commonalities by Designing Production-Oriented Modular Product Platforms

Companies producing in high-wage countries are increasingly challenged due to the necessary differentiation and cost pressure. The modular product platform approach is more and more used by these companies for structuring their product range in order to realise and deploy commonalities. This type of product architecture enables companies to produce nearly individual products without losing economies of scale across the product range. Economies of scale due to communalities result in decreased process costs, reduced development lead-time by uncoupling the development of modules and products as well as the augmentation of the technical product robustness. However, the design of modular product platforms itself causes new challenges regarding the product structuring, the process and organizational design. Recent approaches for the development of communalities through modular product platforms are focusing only the product itself. Since costs are mainly determined in the development phase but caused later in the production phase both product and production have to be taken into account. Furthermore, modular product platforms have a higher variety and diversity of elements since they represent the components, modules and functions of the entire product program. This paradigm shift from an integral product design to a modular product structure cannot be controlled with existing models and methods. Our paper confirms commonality has to be optimized by focusing both the product and production. Therefore we have designed a descriptive framework (commonality model) to display and optimize the commonality both in the product and the process. Furthermore, a product architecture development process that is superior to the individual product development processes was developed for the systematic design of commonalities. The approach presented in this paper focusses on the interactions between product and process parameters. In our approach these interactions will first be displayed based on the graph theory and then be optimized applying sensitivity analysis. By varying relevant parameters both on the product and process side constitutive features can be derived determining product and process standards in order to enhance the overall commonality level.

Systematische Gestaltung von Kommunalitäten in Produkten und Prozessen

Kurzfassung Produzierende Unternehmen stehen zunehmend vor der Herausforderung, ihre Innovationsproduktivität bei erhöhtem Differenzierungszwang und Kostendruck globalisierter Märkte auszubauen. Häufig können Unternehmen in diesem Umfeld Potenziale für Skaleneffekte nicht optimal nutzen, da die zugrundeliegenden Produktarchitekturen heute weitestgehend ungeplant realisiert werden. Eine am Werkzeugmaschinenlabor WZL der RWTH Aachen erstellte Studie zeigt, dass diejenigen Unternehmen besonders erfolgreich Skaleneffekte realisieren, die Module gezielt für den Baukasten entwickeln, statt für einzelne Produkte mit der nachträglichen Möglichkeit zur Übernahme in den Baukasten. Aus dieser Erkenntnis heraus wurde am WZL ein Produktarchitektur-Entwicklungsprozess (PAEP) entwickelt, welcher die systematische Gestaltung von Kommunalitäten unterstützt. [1]

Modular Chassis Product Platform Considering Variable Quantities for an Economical Electric Vehicle Production

Due to the dwindling resources of fossil combustibles electric-mobility becomes more and more an alternative to present mobility. Besides this aspect the ecological awareness puts pressure on the automotive industry. Especially in cities and urban areas pollution and noise become an increasing problem.

Integriertes Controlling von Produkt- und Produktionskomplexität

Stichwörter Komplexitätscontrolling Komplexitätsmanagement Produktionscontrolling Standardisierung Variantenmanagement Im Dilemma zwischen Skaleneffekten und Befriedigung kundenindividueller Bedürfnisse nimmt das Controlling von Produktund Produktionskomplexität eine zunehmend wichtige Rolle ein. In diesem Artikel wird eine Methodik vorgestellt, die eine systematische Unterstützung bei der strategischen Abstimmung zwischen Produkt und Produktion sowie dem operativen Variantenmanagement bietet.

Controlling der Varianzsensitivität in Baukastensystemen

Stichwörter Baukastensysteme Entwicklung Modulare Produktarchitektur Standardisierung In dem Artikel wird eine Methodik vorgestellt, die es erlaubt, Standards in Produktbaukästen systematisch zu gestalten, indem die Auswirkungen variantentreibender Merkmale auf die Wertschöpfungsprozesse bewertet werden. Durch die Identifikation und Bewertung der Einflussfaktoren auf die Varianz kann ein Variantencontrolling für Baukastensysteme realisiert werden. Die Methodik wird abschließend an einem Praxisbeispiel validiert.