Autor: Farian Krohne

In recent years dynamics in the automotive industry has increased rapidly. Beside a higher degree of customer orientation product life cycles become continuously shorter, whereby an over-all effect on Ramp-up and Phase-out Management can be stated. Because of an increasing amount of new model ranges Ramp-up Management has been well discussed during the last few years. In contrast, discussions about an efficient Phase-out Management are mostly still missing. This paper presents an approach focusing on the transparency of information considering the requirements of Production Phase-outs.

Even during ramp-up phases technical product changes are inevitable. Swift and spontaneous reaction is therefore required for meeting the set market entry date. At the same time, risk estimation of different solution alternatives is needed to evaluate the effects of product changes on product and processes. In this context unstructured procedures observed in practice lead to unsatisfactory solutions and unforeseeable effects. This dilemma of product change management has been countered with the development of PMEA (Product Change Mode and Effect Analysis) and its combination with TRIZ (Theory of Inventive Problem Solving).

For an efficient implementation of technical product changes, industrial companies need to use a goal-oriented procedure as well as an effective application of already existing knowledge about previous product changes. Mostly, product changes are implemented by using standardised workflows, which are controlled and documented by common workflow-management-systems. The administration effort of these systems often causes delayed implementation of product changes. In this context companies try to optimise the product change process by implementing new application systems and by integrating existing isolated applications in these systems. The organisation of subgroups, who finally implement the product change, is often neglected. Thereby, the development of new approaches in this area may close the gaps in order to make knowledge available.

In the conflict between greater customer requirements and a diversification in production industry, companies are forced to reduce ramp-up times significantly. The trend towards a continuous reduction of the time-to-market puts pressure on these companies and addresses the realisation of the expected market entry. More often this results in an inefficient production run-up, because the reduction in development time poses an important factor for later product changes. With regard to shorter product life cycles, it is expected that time for production and distribution will be extended. Cost-intensive product changes will reduce profit, which is why product change management becomes more and more important. Nevertheless, the effective management of process changes is not addressed sufficiently by today’s research. These in particular can be defined as most critical factors for an efficient production run-up.

The management of production ramp-up of complex series products is one of the critical success factors for companies. Shorter ramp-up phases become more important for companies because an early time-to-market means extra gains right after market launch. Nevertheless, reduction of production ramp-up is mostly realised by time savings in the phase of product development. This is one of the reasons for a lot of product changes, which occur during production ramp-up and whereby original equipment manufacturers as well as suppliers are forced to renew already used series tools. To reduce unnecessary expense of tool replacement a forward displacement and a faster implementation of technical product changes are required. In this context the product change classification offers significant but until today unused potentials.