Complexity Management - Optimizing Product Architecture of Industrial Products

Foreword

Preface

Brief Contents

Table of Contents

List of Figures

List of Tables

List of Acronyms

Management Summary

Management Summary (Deutsch)

1 Introduction

1.1 Problem Statement

1.2 Research Objectives and Research Question

1.3 Reference Frame

1.4 Methodological Approach

1.5 Thesis Structure

2 Background and Fundamental Concepts

2.1 Complexity as a Challenge for Enterprises

2.1.1 The Two Sides of Complexity

2.1.2 External Complexity – Understanding the Market Needs

2.1.3 Internal Complexity – The Cost Side of Complexity

2.2 The Complexity of Systems

2.3 The Importance of Product Architecture

2.3.1 Definition and Implications of Product Architecture

2.3.2 Modular and Integral Product Architectures

2.4 Concluding Remarks

3 Literature Review: Existing Concepts

3.1 Assessment Criteria

3.2 Managing Complexity on a Conceptual Level

3.2.1 Mass Customization

3.2.2 Lean Management

3.2.3 The Concept of Optimum Variety

3.3 Tools for Managing Complexity

3.3.1 Quality Function Deployment (QFD)

3.3.2 Target Costing

3.3.3 Design for Variety

3.3.4 Design for Configuration

3.3.5 Product Modularization

3.3.6 Modular Function Deployment

3.3.7 Product Platforms

3.3.8 Variant Mode and Effects Analysis

3.3.9 Variety Reduction Program

3.4 Assessment Summary

4 Complexity Management Model

4.1 Overview

4.2 Strategy and Product Life Cycle Assessment

4.2.1 Strategic Considerations

4.2.2 Product Life Cycle Considerations

4.2.3 Summary of Strategy and Product Life Cycle Assessment

4.3 Product Complexity Assessment

4.3.1 Introduction

4.3.2 Quantifying Functionality

4.3.3 Quantifying Physical Complexity

4.3.4 Drawing the Complexity Matrix

4.3.5 Summary of Product Complexity Assessment

4.4 Deriving Guidelines for Action

4.4.1 Introduction

4.4.2 Basic Norm Strategies

4.4.3 Influence of Strategic Considerations

4.4.4 Influence of Product Life Cycle Considerations

4.4.5 Summary of Guidelines for Action

4.5 Summary of Complexity Management Model

5 Case Studies

5.1 Introduction

5.2 Railroad Signal

5.2.1 Introduction to the Case

5.2.2 Application of Complexity Management Model

5.2.3 Result of Optimization

5.2.4 Discussion

5.3 Liquid Handling Platform

5.3.1 Introduction to the Case

5.3.2 Application of Complexity Management Model

5.3.3 Result of Optimization

5.3.4 Discussion

5.4 Process Industry Compressor

5.4.1 Introduction to the Case

5.4.2 Application of Complexity Management Model

5.4.3 Result of Optimization

5.4.4 Discussion

5.5 Railroad Switch Lock

5.5.1 Introduction to the Case

5.5.2 Application of Complexity Management Model

5.5.3 Result of Optimization

5.5.4 Discussion

6 Conclusion

6.1 Reflecting on the Research Achievements

6.1.1 Answering the Research Question

6.1.2 Concluding Model Assessment

6.2 Limitations

6.3 Reflecting on the Research Methodology

6.4 Suggestions for Future Work

Appendix A List of Definitions

Appendix B Classification of Strategies

Appendix C Ballpoint Pen Example

Appendix D Complexity Matrix Calculations

D.1 Calculating Physical Complexity

D.2 Quadrant Borders in the Complexity Matrix

D.3 Taking the Logarithm for Complexity Driver Calculations

Reference List