
Build To Order
The Road to the 5-Day Car
By: Glenn Parry (Editor), Andrew Peter Graves (Editor)
Hardcover | 24 September 2008
At a Glance
460 Pages
24.13 x 15.88 x 3.18
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Industry Reviews
From the review:
This book is interesting and well organised... [T]he editors have been able to well integrate the different contributions proposing a book which appears homogeneous... and well written.
Production Planning & Control Vol. 20, No. 8 (December 2009) (Reviewer: Paulo Gaiardelli)
| Introduction and Overview | p. 1 |
| Drivers and Followers | p. 2 |
| Defining Build-to-Order | p. 3 |
| Advantage of Build-to-Order | p. 3 |
| The Road to Build-to-Order | p. 4 |
| The ILIPT Project | p. 6 |
| Book Structure | p. 8 |
| References | p. 10 |
| Industry Dynamics | |
| The Evolution of Competition in the Automotive Industry | p. 13 |
| All Competitive Advantage is Temporary | p. 14 |
| The Past: The Evolution of Production Systems | p. 16 |
| The Present: Shifts in the Competitive Landscape | p. 20 |
| Regionalisation | p. 22 |
| Fragmentation of Markets | p. 24 |
| Saturation and Overcapacity | p. 25 |
| Structural Changes in the Supply Chain | p. 26 |
| The Future: Competing in the Second Automotive Century | p. 28 |
| What Next? | p. 30 |
| Conclusion | p. 32 |
| References | p. 33 |
| Build-to-Order: Impacts, Trends and Open Issues | p. 35 |
| Introduction | p. 35 |
| BTO: Where Is the Industry? | p. 36 |
| The Obstacles on the Way to Build-to-Order | p. 38 |
| Organisational Obstacles | p. 39 |
| Market-Related Obstacles | p. 42 |
| Supply-Related Obstacles | p. 43 |
| The Impact of Build-to-Order on the Bottom Line | p. 44 |
| The Impact of Build-to-Order on Inventory Levels | p. 45 |
| Product Phase-outs | p. 47 |
| The Impact of Build-to-Order on Order Lead Times | p. 48 |
| Coping Mechanisms | p. 49 |
| The Way Forward | p. 52 |
| References | p. 53 |
| Current Issues at OEMs and Suppliers | p. 55 |
| New Challenges in Product Policy | p. 55 |
| Increased Pressure from Competitors | p. 58 |
| Reactions from the European Automotive Industry | p. 61 |
| Product Strategy | p. 61 |
| Modularisation | p. 64 |
| Construction of a Flexible Production Network | p. 67 |
| Conclusion | p. 72 |
| References | p. 72 |
| Outsourcing: Management and Practice Within the Automotive Industry | p. 75 |
| Introduction | p. 75 |
| Defining the Concept of Outsourcing | p. 77 |
| Approaches to Outsourcing | p. 77 |
| The Resource-Based View - How Can a Company Sustain Its Competitive Advantage in a Dynamic Market Environment? | p. 77 |
| Resource-Dependency Theory - Why Is a Company Dependent on Its External Environment? | p. 79 |
| Transaction Cost Theory - Which Costs to Consider When Making Outsourcing Decisions? | p. 79 |
| Industrial Network Approach - Why Should a Company Consider Its Wider Network? | p. 81 |
| Summary of Outsourcing Approaches | p. 81 |
| The Quest for Competitiveness - Identifying Core and Supporting Activities | p. 83 |
| Outsourcing Supporting Activities in the Automotive Sector | p. 84 |
| The Core Competence Concept in the Automotive Sector | p. 85 |
| Outsourcing Core Activities | p. 86 |
| A Snapshot of Outsourcing Benefits and Risks | p. 88 |
| Outsourcing Benefits | p. 88 |
| Outsourcing Risks | p. 90 |
| Managerial Implications for (Beneficial) Outsourcing Decisions | p. 93 |
| More Attention Should Be Drawn to the Selection of Outsourced Activities | p. 93 |
| Assessing Future Core Activities Properly | p. 93 |
| Be Careful with Customer-Centric Areas | p. 94 |
| Setting out Clear (Contractual) Guidelines | p. 94 |
| Outsourcing Providers Should Be Selected Carefully | p. 94 |
| Outsourcing Relationships Have to Be Managed | p. 94 |
| Conclusion | p. 95 |
| References | p. 96 |
| Modularity | |
| An Overview of Modular Car Architecture: the OEMS Perspective on Why and How | p. 101 |
| Introduction | p. 101 |
| Internal and External Reasons for Modular Car Architecture | p. 102 |
| Requirements for the Production and Supply Chain | p. 104 |
| A Possible Approach to the Design of Modular Automobiles | p. 106 |
| Conclusion | p. 107 |
| References | p. 107 |
| The Modular Body | p. 109 |
| The Idea of Modularity | p. 109 |
| Modularity Concepts | p. 111 |
| DaimlerChrysler Vario Research Car | p. 111 |
| DaimlerChrysler MoCar | p. 112 |
| Fiat Ecobasic | p. 113 |
| General Motors Autonomy | p. 115 |
| Ford Skala | p. 116 |
| Fiat Dual Frame | p. 118 |
| Basic Conditions for Body Design | p. 119 |
| Logistics Requirements | p. 119 |
| Complete Vehicle Structure | p. 119 |
| Assembly Order | p. 120 |
| ModCar Body Design | p. 120 |
| Scope of Research | p. 120 |
| Combination of Modules | p. 122 |
| Tolerance Compensation | p. 130 |
| Conclusion | p. 131 |
| References | p. 131 |
| Modular Concepts and the Design of the ModCar Body Shell | p. 133 |
| Introduction | p. 133 |
| Styling Process and Concepts of the ModCar | p. 134 |
| Technical Engineering of the Outer Panels | p. 138 |
| Choice of Lightweight Materials | p. 138 |
| Partition of the Outer Panels | p. 141 |
| Joining Concepts for Outer Panels | p. 142 |
| Technical Engineering of the Door Module | p. 144 |
| Structural Analyses of ModCar Body Shell Components and Structure | p. 146 |
| Deformation Behaviour of the Modular Door | p. 146 |
| Crash Behaviour of the ModCar | p. 147 |
| Stiffness Behaviour of the ModCar | p. 151 |
| Conclusions | p. 152 |
| References | p. 153 |
| Complexity Cost Management | p. 155 |
| Introduction | p. 155 |
| Product Variety | p. 157 |
| Product Variety in Lean Manufacturing Environments | p. 157 |
| Product Variety in the Automotive Industry | p. 158 |
| Variant-Driven Complexity | p. 158 |
| The Complexity Cost Model | p. 161 |
| Basic Survey | p. 161 |
| Analysis of the Current State | p. 165 |
| Conclusion | p. 173 |
| References | p. 174 |
| Collaboration | |
| Key Principles of Flexible Production and Logistics Networks | p. 177 |
| Collaborative Planning Processes | p. 181 |
| Approaches to Coordinating "Collaborative Planning" | p. 181 |
| Hierarchical Organised Coordination | p. 182 |
| Decentralised Coordination | p. 183 |
| Existing Approaches of Collaborative Planning | p. 184 |
| The Architecture of the BTO Production Network | p. 185 |
| The Process of Collaborative Planning | p. 188 |
| The Local Planning Process | p. 191 |
| Autonomous Behaviour and Collaboration in Supply Networks | p. 192 |
| Agent-Based Collaborative Planning | p. 193 |
| Conclusion | p. 206 |
| References | p. 207 |
| Collaborative Execution Processes | p. 209 |
| The Current Situation in the Automotive Industry | p. 210 |
| The Role of the BTO/BTS Border in a Pure BTO Manufacturing System | p. 210 |
| Order Management for a Pure BTO Manufacturing Environment | p. 211 |
| Order Types | p. 211 |
| Order Management | p. 212 |
| Order Entry | p. 213 |
| Assembly Scheduling | p. 215 |
| Call-Off to the BTO Suppliers | p. 216 |
| Replenishment of BTS Parts and Materials | p. 217 |
| Exception Handling | p. 217 |
| Execution Prototype | p. 219 |
| Module Deployment and the Software Required | p. 219 |
| Conclusion | p. 220 |
| References | p. 221 |
| Functionalities of Supporting IT Systems: Current Situation, Future Requirements and Innovative Approaches | p. 223 |
| Process Requirements of Information Technology | p. 223 |
| Capabilities of Current IT Systems | p. 225 |
| Distributed Information Management | p. 226 |
| Interoperability Framework | p. 227 |
| Application Interoperability | p. 228 |
| Service Interoperability | p. 229 |
| Data Interoperability | p. 230 |
| Infrastructure Interoperability | p. 231 |
| Modelling Data and Semantics | p. 231 |
| Structure Ontology | p. 232 |
| Planning Ontology | p. 233 |
| Execution Ontology | p. 234 |
| Systems Architecture | p. 235 |
| Concluding Remarks on IT Functionality | p. 236 |
| References | p. 237 |
| Modelled Scenario Examples for Planning and Execution Processes | p. 239 |
| Basic Structure for the BTO Demonstrator Model | p. 239 |
| Scenario Examples for the Collaborative Planning Process | p. 242 |
| Collaborative Planning - Scenario 1 | p. 243 |
| Collaborative Planning - Scenario 2 | p. 244 |
| Collaborative Planning - Scenario 3 | p. 246 |
| Scenario Examples for the Collaborative Execution Process | p. 247 |
| Execution Planning - Scenario 1 | p. 250 |
| Execution Planning - Scenario 2 | p. 251 |
| Execution Planning - Scenario 3 | p. 252 |
| Conclusion | p. 254 |
| Validation | |
| A BTO Reference Model for High-Level Supply Chain Design | p. 257 |
| Introduction: Motivation and Objectives for a Build-to-Order Reference Model | p. 257 |
| The Idea Behind a Build-to-Order Reference Model | p. 259 |
| A Classification Framework for Automotive Build-to-Order Concepts | p. 261 |
| A BTO Target System | p. 262 |
| BTO-Related Problem Areas and Associated Fields of Action | p. 263 |
| Process Flexibility | p. 264 |
| Process Stabilisation | p. 265 |
| Process Standardisation | p. 265 |
| Process Acceleration | p. 265 |
| Process Transparency | p. 266 |
| Process Synchronisation | p. 267 |
| Failure Prevention and Reaction | p. 267 |
| Summary and Conclusion | p. 267 |
| An Integration Framework for BTO Concepts | p. 270 |
| Supply Chain Design Procedure Model | p. 272 |
| Model Design | p. 273 |
| Data Acquisition and Preparation | p. 273 |
| Modelling and Verification | p. 274 |
| Computation and Simulation | p. 274 |
| Analysis | p. 274 |
| Documentation | p. 275 |
| Summary and Outlook | p. 275 |
| References | p. 275 |
| Rapid Supply Chain Design by Integrating Modelling Methods | p. 277 |
| Introduction | p. 277 |
| The Challenge at Hand | p. 277 |
| Goal | p. 278 |
| Supply Chain Design | p. 279 |
| Framework Conditions of Supply Chain Design | p. 279 |
| Defining Supply Chain Design | p. 280 |
| Requirements for the Supply Chain Design Process | p. 281 |
| Modelling and Evaluating Value Creation Networks | p. 283 |
| Modelling | p. 283 |
| Modelling Methods in Supply Chain Design | p. 283 |
| Assessing the Modelling Methods | p. 287 |
| An Integrated Method for Supply Chain Design | p. 289 |
| Supply Chain Design Process for the Integrated Method | p. 290 |
| Implementing the Integrated Method | p. 291 |
| Application Cases | p. 292 |
| Global Networks Facing Increased Market Demand | p. 292 |
| Product Design for Logistics | p. 293 |
| Strategic Network Design for Future Automotive Production | p. 293 |
| Conclusion | p. 294 |
| References | p. 294 |
| Moving Towards BTO - An Engine Case Study | p. 297 |
| Scope of the Case Study | p. 297 |
| Current State Processes | p. 298 |
| To-Be BTO Processes | p. 299 |
| Application of the Combined Approach and Model Scope | p. 300 |
| Objectives of the Case Study | p. 301 |
| Model Scope | p. 301 |
| Results of the Case Study | p. 303 |
| Results of the Static Analysis | p. 303 |
| Dynamic Evaluation of the New Process Concept | p. 305 |
| Integration of Second-Tier Suppliers into BTO Concepts | p. 307 |
| Key Results | p. 309 |
| Conclusion and Outlook | p. 310 |
| How the Electro-Mechanical Valve Train Accelerates Logistics and Reduces Costs | p. 311 |
| Introduction | p. 312 |
| Technical Description of the MVVT Compared with the EMVT | p. 314 |
| Production and Logistics Benefits of the EMVT | p. 316 |
| Comparing the Assembly Process | p. 317 |
| Comparing the Storage Process | p. 319 |
| Comparing the Logistics Network | p. 319 |
| Conclusion | p. 321 |
| References | p. 322 |
| Network Design for Build-to-Order Automotive Production | p. 323 |
| Introduction to Automotive Value Creation Networks and Build-to-Order Supply Chain Design | p. 323 |
| Alternative Designs for Automotive Value Creation Networks | p. 325 |
| Component Supply | p. 325 |
| Vehicle Assembly | p. 326 |
| Distribution Network | p. 327 |
| Model-Based Evaluation of Design Alternatives | p. 329 |
| Characteristics of the Model Employed | p. 329 |
| Results | p. 330 |
| Conclusion | p. 333 |
| References | p. 334 |
| Implementation | |
| Automotive e-hubs: Exploring Motivations and Barriers to Collaboration and Interaction | p. 337 |
| Introduction | p. 337 |
| Reviewing the e-hub: Theory and Practice | p. 338 |
| e-hub Classification | p. 338 |
| Current State of the Automotive Market | p. 340 |
| Motivations and Barriers | p. 342 |
| Approach to Developing the Framework | p. 345 |
| Automotive Case Analysis | p. 346 |
| Case 1: "Motorco" | p. 346 |
| Case 2: "Carco" | p. 347 |
| Case 3: "Partco" | p. 349 |
| Case 4: "Lampco" | p. 350 |
| Discussion: Revisiting the Framework | p. 353 |
| Contribution to Theory and Practice | p. 356 |
| Conclusion | p. 357 |
| References | p. 358 |
| Automotive Supplier Park Strategies Supporting Build-to-Order | p. 361 |
| Introduction | p. 361 |
| Background | p. 362 |
| The Objectives of Build-to-Order | p. 362 |
| What ARe Supplier Parks? | p. 363 |
| Motivations for Supplier Parks | p. 364 |
| Other Factors That Affect Supplier Parks | p. 365 |
| Data Collection | p. 368 |
| The Reality of Automotive Supplier Parks | p. 369 |
| Supplier Park Descriptions | p. 370 |
| Discussion | p. 373 |
| Supplier Parks That Enable BTO | p. 375 |
| Supplier Parks with the Potential to Enable BTO | p. 375 |
| Supplier Parks That Do Not Enable BTO | p. 376 |
| Supplier Parks: Imperative for Build-to-Order? | p. 377 |
| Conclusions | p. 377 |
| References | p. 379 |
| Managing the Transition to the "5-Day Car" in Europe | p. 383 |
| Introduction | p. 383 |
| Why Build-to-Order? | p. 384 |
| The Demand for Build-to-Order | p. 387 |
| Supply Chain Readiness | p. 388 |
| Resistance to Change | p. 388 |
| Company Ownership and Overcapacity as Potential Barriers | p. 389 |
| The Industry Executives' Perspective | p. 390 |
| Consultation Findings | p. 390 |
| Enablers to Effective Transition | p. 392 |
| Building on Existing Good Practice in BTO | p. 393 |
| Training and Education | p. 393 |
| Clear Planning and Objective Setting | p. 394 |
| Aligning Key Performance Indicators | p. 395 |
| Enhancing Supply Chain Learning | p. 396 |
| Communication and Benchmarking Progress | p. 397 |
| Conclusion | p. 397 |
| References | p. 398 |
| The Road Ahead | |
| The Road to the 5-Day Car | p. 403 |
| Introduction | p. 403 |
| Social Pressure and Government Challenge | p. 404 |
| Industry's Challenge | p. 405 |
| Conclusion | p. 407 |
| About the Editors | p. 409 |
| About the Authors | p. 411 |
| ILIPT Members | p. 419 |
| Glossary | p. 425 |
| Index | p. 429 |
| Table of Contents provided by Ingram. All Rights Reserved. |
ISBN: 9781848002241
ISBN-10: 1848002246
Published: 24th September 2008
Format: Hardcover
Language: English
Number of Pages: 460
Audience: Professional and Scholarly
Publisher: Springer Nature B.V.
Country of Publication: GB
Dimensions (cm): 24.13 x 15.88 x 3.18
Weight (kg): 0.93
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