Infosys delivers high value global engineering solutions across the product lifecycle value chain. This blog is to discuss trends and best practices around global engineering, global product development, product innovation, product lifecycle management and green engineering aspects across industries.

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February 25, 2010

Accelerating product value realization with Product Effectiveness

Rapid introduction of reliable, compelling products is the lifeblood of product companies.  Also, successful new product launches are highly rewarding in terms of higher margins they promise.  However, the reality of product innovation is that the failure rate of new products is high.  This is not affordable or sustainable, given the pressure on scarce resources.  Imagine the impact if the new product success rate were to increase only a few percentage points – benefits would flow straight to the bottom line.

PLM solutions have been offered by technology vendors as a panacea for all product development ills. However, these solutions have seen limited adoption compared to enterprise applications for a variety of reasons:

  • While there are many systems available today, organizations still lack a direction on what solution to choose and how to implement across global extended enterprise to address their specific needs, accelerate value realization  and provide sustainable governance
  • Implementation is done at a departmental level, typically at engineering design centers, rather than managing the product information at an enterprise level
  • Solutions until recently have not contained portfolio management and product intelligence capabilities, with linkage to financials and dynamic resourcing functionality
  • Product development process maturity is not as mainstream as areas like supply chain, and correspondingly has not received appropriate management attention
  • While individually the process may be well defined for each product function, there are significant areas of ambiguity across groups that are not effectively addressed under the conventional stage-gate process

Part of the problem with traditional approaches has been an emphasis on process, without considering other dimensions of change.  There needs to also be robustness, collaboration, repeatability, and synchronization of effort by all product functions.  Companies need a broader, perhaps transformation view to the product development process.  The term Product Effectiveness has been coined to describe this multi-dimensional framework and approach. Business leaders seek to go beyond conventional product development to create better product value through multiple dimensions – new product introduction capabilities, dynamic management of products to generate profitable portfolio, ironing out post-sales product performance issues, and most importantly, Voice of the Customer.  Some refer to this as Extended PLM, since it can be implemented in organizations with or without a PLM implementation in place.

The Product Effectiveness framework is made up of 12 components Product Effectiveness incorporating industry operations references models from the Supply Chain Council, PDMA, and leading academic institutions.  The framework address a matrix of process (product management, product development and product sustenance) and domain (customer needs management, NPDI program management, product portfolio, and product performance).  The following 12 components comprise the framework:

  • Product strategy
  • Product value management
  • Portfolio decisions
  • Product intelligence
  • Product requirements
  • Lifecycle management architecture
  • Product innovation management
  • R&D testing and laboratory management
  • NPD knowledge management
  • Process harmonization
  • Diagnosis and root cause analysis
  • Compliance

These 12 components are not meant to be all inclusive – rather, they are the areas to ‘get right’ when describing the product lifecycle and offer a starting point when defining and planning improvement initiatives.

Beyond the components, it is also useful to consider tools and aids for performance improvement.  Tools can provide the rigor and consistency to drive change throughout the enterprise, and tools are needed to make the change permanent by enabling maintenance as things change over time.  Following are standard tools that leaders should consider for performance improvement:

  • Capability maturity profiles
  • Data models
  • Product roadmaps
  • Process reference models
  • Metrics libraries
  • Workflows
  • Business intelligence and reporting

To bring these ideas together, companies should take a holistic approach.  Many failed improvement initiatives have been caused by a piecemeal approach and lack of the bigger picture.  Here are some leading practices for improvement initiatives in the area of product development and management:

-    Assessment to determine NPDI maturity level to develop an initiatives roadmap
-    Adhere to industry standard process models, product data models and KPI
-    Reduce decision making time by enabling quick go-kill-hold decisions
-    Improve enhance productivity through accelerators embedded as part of the new process model
-    Determine product value and track portfolio profitability over periods of time
-    Provide executive window into broader dynamics of cross-functional product development cycle

The ideas above may not be the total story.  However, they should provide leaders in product companies a starting point to refine their existing approach or perhaps shape planned improvement initiatives.  One thing is for sure:  with the intense pressure to simultaneously increase innovation and reduce cost, anything that can improve product effectiveness will help companies compete more effectively and reward their stakeholders.

 

 

 

October 29, 2009

Knowledge Based Solutions can keep the Aviation industry afloat…

At an average the net profit margin of the airline industry stands at around 2-3%. How can this profitability be enhanced further for long term sustenance of the industry? The key lies in the current cost structure of airlines. According to various statistics, the cost contribution for the airlines is projected as fuel cost 49%, aircraft cost 18%, crew cost 14%, maintenance cost 14% and others 5%. Costs like fuel and aircraft are beyond the control of airlines and are driven by many external factors. The next biggest cost is maintenance and airline industry can directly control this cost by improving its effectiveness and efficiency. Typically maintenance of air fleet consists of both scheduled and unscheduled maintenance activities. Scheduled maintenance involves daily checks, A, B, C, D checks. There is about 60% chance of having damages found in these checks which require repair. The unscheduled maintenance include repair of unforeseen damages caused by events like bird hit, hail storm, lightening strike etc.  It is essential to shorten the repair cycle time and increase the availability of aircrafts for operations. This is evident from the fact that each aircraft on the ground cost is estimated to be about $100k per day.  

Further introspection and analysis would help to address this problem. The cost of maintenance includes both material and labor cost. In this labor cost can be reduced to sizable extent by using advanced technologies like knowledge based engineering (KBE). Let us look at more carefully the entire repair and maintenance cycle of airframe. Through knowledge based solutions, costs involved in activities given below can be reduced drastically
        Managing manuals like Structural repair manuals (SRM), Component Maintenance Manuals (CMM), Aircraft Maintenance Manuals (AMM) etc
        Finding and following the instructions given in manuals
        Diagnosing and assessing the damage
        Identifying repair solution from manuals
        Preparation of repair procedure and documentation
These activities consist of about 22% of the total labor costs of airframe maintenance. A conservative estimate shows that this can be reduced to about 5% by using knowledge based solutions. Hence, about 17% savings can be realized.

Knowledge based solutions and Knowledge Based Engineering (KBE) in particular is based on capturing repair and maintenance knowledge and embedding this knowledge into a web based systems (KBE system) and utilize such system in the repair and maintenance of aircraft.  For example, if we look at the SRM manuals alone, there are voluminous documents. It is also not easy to interpret them to identify a repair solution for a typical damage. The situation is even more complex for composite based aircrafts whose documents will be much more voluminous compared to metallic aircrafts. Think of an equivalent web enabled, knowledge based system which can provide repair solution based on certain queries from the users. This will replace static voluminous documents with an expert system. In earlier days technology was not matured enough to create such advanced systems. Now this is certainly possible. There are many such scenarios where we are collaborating with our customers to leverage technology and in particular knowledge based solutions for enhancing effectiveness and efficiency of engineering and maintenance activities towards driving up the profitability of the industry.

Do you see any such trends in the industry you operate?

September 25, 2009

For lean implementations, Value Stream Mapping (VSM) is good… but Value Stream Simulation (VSS) is certainly better

Be it a shop floor or an engineering office or a call center or even a hospital or any other operations, the primary objective behind lean implementations is to identify and eliminate non-value added (waste) elements continuously. Making waste elements visible in a value stream is not so simple and straight forward.  On the other hand, automating or replicating (for implementing at multiple locations) processes without improving (leaning out) it can accelerate the inherent waste creation that could lead to disastrous outcomes.

One of the prominent techniques adopted by lean experts to capture and analyze operations for improving is Value Stream Mapping (VSM). In brief, VSM is a process of mapping out the entire process flow, material and information flows along with details about value added and non-value added elements, with inputs from the stakeholders. VSM is a proven technique applied by many lean experts across the industry verticals. However, VSM evolved many decades ago when there were not many easy to use, computer assisted solutions existed. VSM works pretty well for simple processes. However, deeper understanding of the process dynamics and inter dependencies for more accurate insights and decision making through VSM can be cumbersome. Capturing a complex process in a static two dimensional VSM representation is too difficult to achieve. For example, a manufacturing process involving multiple product mix, multiple cycle times, process variability, infrequent operations (e.g loading the raw material every 500 cycles or setting a tool every 1000 cycles), shared resources, exception handling (like minor & major repairs, minor & major break downs, buffer run outs, dynamic prioritizing etc) can become too laborious and error prone to capture and analyze through VSM alone.

Value Stream Simulation (VSS) models built leveraging discrete event simulation tools provide closer to real-life representation of complex operations (and processes) enabling deeper insight into the process dynamics and interdependencies. This provides the lean implementation teams with more accurate representation of the physical system for better analysis and decision making. The ability to quickly run what-if scenarios with simulated stochastic variability as per real-life probability distributions provides close to real life mathematical model of the system for evaluating multiple scenario outcomes. Enhanced visualization capabilities of space and time (3D) help the users to quickly understand the behavior of the system. VSS helps in arriving at dynamically validated lean model of operations with very high confidence levels on proposed modifications and outcomes.

Hence, be it upfront planning of lean operations or lean implementation in existing operations, certainly Value Stream Simulation (VSS - dynamic VSM) approach provides deeper insights into the operations enabling better decision making  than 2D, static VSM approach. We have recently applied the VSS approach for dynamic VSM and simulation of manufacturing shop floors; business processes (call center operations) of a fleet management company and the outcomes are very impressive. Of course, it involves additional tools and expertise for modeling through VSS. But, customers can leverage Global Engineering teams (like Infosys) for building the VSS model of their operations for their lean implementation initiatives, with minimum involvement during initial data collection and value stream understanding.  

A picture (VSM) is worth thousand words but a Dynamic Value Stream Simulation (VSS) is worth thousand pictures…

August 28, 2009

Global Engineering and Product Operations – The Strategic Imperative

How can companies compete in an environment of excess supply while preparing for a market upturn?  This is a strategic question facing companies today, and effective product operations and engineering are fundamental to address the challenge. 

Continue reading "Global Engineering and Product Operations – The Strategic Imperative" »

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