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© WZL/Fraunhofer IPT
Sustaining Capability for Innovation: A German Perspective Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University
6th Annual Manufacturing Summit at MIT
Boston, October 28th 2011
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Quick, marketable innovations are the key success factor for high-wage countries
Source: WZL, BTM Consult ApS – 26 March 2007, World Wind Energy report 2008 -2010
Success factors for Germany as a high-wage country
1. Achievement of a price premium by offering differentiated products fitting to heterogeneous market needs
2. The use of commonalities offers the possibility of multi-variant product portfolios at high manufacturing productivity and competitive prices
3. Reduction of the risks of imitation by highly innovative products
+53000 (759%)
+40000 (98%) +35000
(386%)
Newly installed wind power capacity (in MW) between 2006 and 2010
Asia 72%
13%
Europe
USA
15%
Production of wind power plants: Market share
Example: Wind power
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Innovation by alignment of product and production
Only manufacturers achieve sustainable product innovation leverage – a German perspective
Product (Innovation)
Production (Innovation)
Internal & external
value chain
Sales market
Alignment of product innovation with customer needs
by proximity to sales market
Assuring and improving manufacturability of products by proximity to production
Missing link for Asian manufacturers?
Missing link for U.S. firms?
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The three major objectives for manufacturing in high-wage countries
Innovation
Individuality Manufacturing Productivity
Meeting heterogeneous market needs by offering a diversified product range
Sustaining productivity of manufacturing by standardization of products and processes
Keeping up with dynamic advancement of customer needs and technologies by rapid evolution of products
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The three major objectives form a trilemma for manufacturing in high-wage countries
Trilemma of Manufacturing in
High-wage Countries
Innovation
Individuality Manufacturing Productivity
Management of product and process diversity ties up
capacities for actual innovation
Standardization of product and processes constrains degree of
freedom for innovation
Increase in product individualization results in a
reduced level of economies of scale
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Reduction of the dilemma between individuality and commonality by definition of intelligent product and process standards
Sources: Volkswagen Sachsen GmbH, Volkswagen AG, Audi AG, Skoda auto a.s., Seat s.a.
Standardized rear-axle interface
Standardized technical length
Standardized assembly sequence
Stan
dard
s
in p
rodu
ct a
rchi
tect
ure
and
prod
uctio
n
Div
ersi
ty
of p
rodu
ct
rang
e
Sub-Compact Compact Medium Coupe Crossover Transverse Modular Product Architecture (MQB) at Volkswagen
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Harmonization of product and manufacturing by integrative standardization
Sources: Audi MediaServices, Autoreport.at
Product
Production
Standardized reference and lifting points constitute available design set for structural parts of car body
Standardized reference and lifting points allow for standardized processes
and equipment
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The intelligent definition of standards not only effects manufacturing productivity but also innovation
Sources: Volkswagen AG
„Several models will get realizable at all, because they become profitable with the new modular product architecture.“ Dr. Ulrich Hackenberg, Head of Product Development at Volkswagen
Effects on innovation Effects on manufacturing productivity
100%
50%
0%
+10%
MQB
70%
PQ35
60%
2
4
0 PQ35
+98%
MQB
3,79 1,91
Sold units (milion units in 2016)
Percentage of common parts
The resolution of the individuality-commonality dilemma by implementation of the right level of standardization allows for freeing up capacity for innovation.
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Alignment of product architecture and production structure for machine tools at MAG Corcom
Flow assembly RT
Shipping/ Receiving
RT ass.
Com
mis
sio-
ning
Spi
ndle
Test
bed
spin
dle
Assembly spindle HMC
Demounting repair spindle
Ship-ping
Ship-ping
Quality control
Manufaturing spindle shaft
Manufaturing spindle housing
Manufaturing rotary table
Tool pre-setting
Technical Laboratory
Manu-faturing special
parts
Receiving Man
ufat
urin
g m
ediu
m p
arts
(N
BH
290/
NB
H35
0)
Manufaturing special parts
Box assembly RT
Commissioning rotary table
SM
RT
SM
spi
ndle
Kanban
material
Assembly spindle TC
Product
Production
Standardized value streams constitute product architecture for machine tool program
Standardized product architecture enables
defined value streams in manufacturing
Sources: MAG Corcom GmbH
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Standardized spindle diameter
Standardized packaging of axial drives
Friction honing
By the implementation of commonalities, niche markets can be opened up economically
Bore honing Peak honing
Plateau honing
Cyl
inde
r he
ads
Cra
nk-
case
s
Gea
r ho
usin
gs
Shi
ft sl
ider
ho
usin
gs
The technology of honing could be opened up economically applying the standardized product architecture
Spherical honing
Threading
Areas of application
Precision turning Drilling Milling
Cyl
inde
r bu
shin
gs
Gea
r w
heel
s
Pis
ton
ro
ds
Sources: MAG Corcom GmbH
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Resolution of the trilemma of manufacturing by harmonization of product and innovation
Accurate level of standardization allows for actual innovation
Regularized individuality frees up capacity
for innovation
Innovation
Manufacturing Productivity Individuality
Harmonized standardization of product and
manufacturing decouples individuality and
manufacturing productivity
Conclusions:
n There is a trilemma for production in high-wage countries between innovation, individuality and manufacturing productivity
n By definition of harmonized standards for product and production the trilemma can be resolved
n This harmonization necessitates a deep understanding of the product and the sales market as well as the production including the entire value chain
à Only manufacturers achieve sustainable product innovation leverage
© WZL/Fraunhofer IPT
Thank you!
Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Phone: +49 241 80 - 27404 Fax: +49 241 80 - 22293 Email: [email protected]
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Appendix
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Integrative product architecture and production research at RWTH Aachen Campus
Concept of RWTH Aachen Campus n Enrollment of companies at RWTH Aachen
University n Joint research and education with labs and
institutes of the university n Direct transfer of knowledge and advanced
training
Demo Factory at Logistics Research Cluster