Product Customization

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1

2 Product Customization

3 Lars Hvam Niels Henrik Mortensen Jesper Riis Product Customization 123

4 Lars Hvam Technical University of Denmark Building 425 DK2800 Lyngby Denmark Jesper Riis GEA Niro Gladsaxevej 305 DK2860 Søborg Denmark Niels Henrik Mortensen Technical University of Denmark Building 404 DK2800 Lyngby Denmark ISBN e-isbn DOI / Library of Congress Control Number: c 2008 Springer-Verlag Berlin Heidelberg This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Production: LE-TEX Jelonek, Schmidt & Vöckler GbR, Leipzig Cover design: WMX Design GmbH, Heidelberg Printed on acid-free paper springer.com

5 Preface This book describes a procedure for designing configuration systems. These systems are used to an increasing extent in industry to support the task of specifying products seen in relation to, for example, sales and production. The procedure involves analysis and redesign of the business processes which can be supported by a configuration system, analysis and modelling of the company s product range, selection of configuration software, programming the software, and implementation and further development of the configuration system. In this book we have chosen to focus most of our attention on the initial phases of the procedure, involving analysis and redesign of business processes and modelling of the product range. The book covers a relatively large number of technical disciplines, which we have attempted to deal with by dividing up the content among us. The authors of the individual chapters are: 1, 2, 4 and 9: Lars Hvam, 5: Niels Henrik Mortensen and Lars Hvam, 3: Lars Hvam, Jesper Riis and Niels Henrik Mortensen, 6, 7 and 8: Jesper Riis and Lars Hvam. Chapter 9 describes some experiences with the use of configuration systems at F.L. Smidth A/S. In this connection we would like to thank Line Hemmingsen, Michael K. Nielsen and Morten Hugo Bennick for an excellent collaboration, and for setting aside the time to discuss their experiences with product configuration and sharing them with us. The starting point for the procedure which we describe here was Lars Hvam s Ph.D. project, Application of product modelling seen from a work preparation viewpoint. The original procedure has subsequently been developed further in Ph.D. projects carried out by Benjamin Loer Hansen, Jesper Riis and Martin Malis, under the supervision of Lars Hvam, by Carsten Svensson under the supervision of Ari Barfod and Lars Hvam, and by Ulf Harlou under the supervision of Niels Henrik Mortensen. A vital factor in the development of the procedure described here has been that we have had a close collaboration over the last 10 years with a number industry and service companies on the design and use of configuration systems. This collaboration has been mediated through the Ph.D.

6 vi Preface projects mentioned above, and by more than 60 M.Sc. thesis projects supervised by Niels Henrik Mortensen and Lars Hvam. We would like to thank Robin Sharp of Translator Data for translating the book into English and Morten Kvist for producing the final version of the figures and the layout. Lyngby, August 2007 Lars Hvam Niels Henrik Mortensen Jesper Riis

7 Table of Contents contents 1 Introduction 1 Doors Inc. 4 2 Specification 3 The Processes and Product Configuration 17 Specifications 18 Specification processes 19 Mass customization and specification processes 23 Development and use of modules 30 Product models and configuration systems 33 Bibliography 40 Procedure 43 The object-oriented project life cycle 48 The procedure for developing configuration systems 51 Development of specification processes (phase 1) 58 Analysis of product range (phase 2) 59 Object-oriented modelling (phase 3) 64 Object-oriented design (phase 4) 77 Programming (phase 5) 80 Implementation (phase 6) 82 Maintenance and further development (phase 7) 83 Concluding remarks 87 Bibliography 87

8 viii Table of contents 4 Development 5 of Specification Processes 89 The process of developing specification processes 90 Step 1: Identifying and characterizing the most important specification processes 92 Situation at Doors Inc. 98 Step 2: Analysis of requirements for the specification processes 102 Doors Inc.: Discussion of targets 114 Step 3: Designing the future specification process. Definition of configuration system 120 Doors Inc.: Designing a new specification process 122 Step 4: Evaluation and choice of solution 126 Doors Inc.: Evaluation of scenarios 128 Step 5: Plan of action and organisation of further work 132 Doors Inc.: Action plan for performing scenario Summary of phase 1 in the procedure 136 Bibliography 137 Analysis of the Product Range 139 The product programme s readiness for configuration 142 Theoretical background for analysis of product range 147 Product variant master 152 Product range analysis at Doors Inc. 165 Working method in analysing the product range 168 Bibliography 170

9 Table of contents ix 6 Object-Oriented Modelling 171 Basic concepts of object-oriented modelling 171 Object-oriented analysis (OOA) 176 Developing an OOA model for Doors Inc. 190 Bibliography Knowledge 8 Choosing Representation and Forms of Reasoning for Expert Systems 197 Artificial intelligence, knowledge-based systems and expert systems 197 Characterization of expert systems 199 Structure of expert systems 202 Forms of knowledge representation in the knowledge base 205 Reasoning in the expert system 211 Bibliography 216 Configuration Software 219 What is a standard system? 219 An overview of forms of programming 222 Criteria for choosing standard software for product configuration 225 Criteria for choosing software 226 Criteria for choosing supplier 232 Examples of programming expert systems 235 Bibliography 238

10 x Table of contents 9 Product Configuration at F.L. Smidth 239 Phase 1: Analysis of specification processes 241 Phase 2: Product analysis 256 Phase 3: Object-oriented analysis 263 Phase 4: Object-oriented design. Choice of software 269 Phase 5: Programming 269 Phase 6: Implementation 272 Phase 7: Maintenance and further development 273 Conclusion 274 Index 281

11 Abbreviations AI API AS-IS model BPR Artificial Intelligence Application Programming Interface Business Process Reengineering Interface for communication with external IT systems Model of an existing system Method for development of business processes CAD Computer Aided Design IT systems for drawing products in 2D or 3D CASE CIM-OSA CNC CRC card CRM Computer Aided Software Engineering Computer Integrated Manufacturing Open System Architecture Computer Numeric Control Class Responsibility Collaboration Card Customer Relation Management Systems for supporting development and maintenance of IT systems Reference model for software for industrial enterprises Computer-controlled production machines Card for describing object classes IT systems for managing customer data DDE Dynamic Data Exchange Communication between different IT systems under Windows Communication between different IT systems under Windows ERP Enterprise Resource Planning IT systems for managing resources such as materials, machines and personnel within companies

12 xii Abbreviations OCL ODBC OLE Object Constraint Language Open Database Connection Object Linkage & Embedding Notation for modelling of constraints Definition of interface to databases Method for importing objects into IT systems under MS-Windows OOA Object-oriented analysis Method for analysis of the application area for an object-oriented IT system OOD Object-oriented design Method for design of object-oriented IT systems PDM PEST SCM SWOT TO-BE model UI UML Product Data Management systems Political, Economical, Sociological, Technological Supply Chain Management Strength Weaknesses Opportunities, Threats User Interface Unified Modelling Language IT systems for managing product data Description of a company s political, economical, sociological and technological status Management of supply chains (suppliers) Description of a company s strengths, weaknesses, opportunities and threats Model of a future system Standard technique for modelling objectoriented IT systems