Optimal overlapping and functional interaction in product development

Overlapping of development stages and interaction between different functions are regarded as important strategies for reducing development lead time. However, overlapping typically requires additional costs for rework and functional interaction increases communication time. This paper presents an analytical model to improve project performance by balancing the positive and negative effects of overlapping and functional interaction. We first investigate the progress of downstream development, which is essential to derive the optimal overlapping policies. We find that the downstream progress increases over time when the upstream evolution is fast or linear, but it is indefinite when the upstream evolution is slow. Then, we present optimal overlapping policies taking into account the complexity of downstream progress. The impact of different project properties, such as the dependency between development stages and the opportunity cost of time, on overlapping policies is discussed. Finally, we derive the optimal functional interaction strategy when the optimal overlapping is followed. The methodology is illustrated with a case study at a handset design company.     

Managing the exchange of information in product development

In the present paper, we develop a dynamic programming (DP) model of the product development (PD) process. We conceptualize product development as a sequence of decisions: whether to incorporate a piece of information that just arrived (i.e. became available) or wait longer. We utilize this formulation to analyze different situations that depend on the type, and nature of information that is exchanged: stationary versus dynamic information. We derive optimal decision rules to determine whether (and when) to incorporate for each case. An analysis of the model results in several important findings. First, we must not necessarily incorporate all available information that is related to the design activity. Specifically, once the information collection exceeds certain value, the design team should stop collecting further information. Second, only when past design work accumulates to a certain threshold value should the team include the latest information and perform rework. Large uncertainty of the information and large sensitivity of the design activity makes the incorporation of new information less likely. Finally, managerial implications are discussed with several numerical examples.     

Optimal testing strategies in overlapped design process

Testing is an important activity in product development. Past studies, which are developed to determine the optimal scheduling of tests, often focused on single-stage testing of sequential design process. This paper presents an analytical model for the scheduling of tests in overlapped design process, where a downstream stage starts before the completion of upstream testing. We derive optimal stopping rules for upstream and downstream stages’ testing, together with the optimal time elapsed between beginning the upstream tests and beginning the downstream development. We find that the cost function is first convex then concave increasing with respect to upstream testing duration. A one-dimensional search algorithm is then proposed for finding the unique optimum that minimizes the overall cost. Moreover, the impact of different model parameters, such as the problem-solving capacity and opportunity cost, on the optimal solution is discussed. Finally, we compare the testing strategies in overlapped process with those in sequential process, and get some additional results. The methodology is illustrated with a case study at a handset design company.     

Structuring product development processes

This paper proposes operational frameworks for structuring product development processes. The primary objective of this research is to develop procedures to minimize iterations during the development process which adversely affect development time and costs. Several procedures are introduced to restructure the development process. The computation of the corresponding product development times is facilitated by two Markov models addressing different types of learning. The methodologies are employed to identify a set of managerial concerns in restructuring the product development processes.The developed framework has become an integral part of a re-engineering project for the development of rocket engines at Rocketdyne Division of Rockwell International. Throughout the paper, the methodologies are illustrated with the help of this process.     

Warranty and optimal reliability improvement through product development

For products sold with warranty, the warranty servicing cost can be reduced by improving product reliability through a development process. However, this increases the unit manufacturing cost. Optimal development must achieve a trade-off between these two costs. The outcome of the development process is uncertain and needs to be taken into account in the determination of the optimal development effort. The paper develops a model where this uncertainty is taken into account.     

A representation model for the solving-time distribution of a set of design tasks in new product development (NPD)

Given the potential risks of new product development projects (NPD), the characteristics of the design tasks solving-time distributions are critical for their effective management. In OR we need to find what operational characteristics of design tasks may delay projects. Other researchers already identified the technological novelty, the magnitude of the design tasks, the interactions between design tasks in an NPD project, and the balancing between projects among the most important causes of the unpredictability of the design tasks lead times in NPD projects.     

Overlapping design and build cycles in product development

Product development time is a major component of the total time it takes to bring a product to market. Overlapping is the process of starting a downstream operation (such as manufacturing) before completing the upstream operation (such as design). There is an inherent risk in overlapping as a build-assembly may not be compatible with a subsequent assembly, requiring reconciliation work on the overlapped tasks. The ensuing trade-off between this risk, and the project time saved, is shown to possess some unique characteristics among different modes of overlapping. We study the optimization model of the trade-off in general, and analyze some special cases to establish interesting insights on overlapping. These include: advantage of overlapping in different scenarios, special properties of optimal overlap, and impact of parameter values on overlapping decisions. We show that several properties of a single overlap can be extended to multiple overlaps, and establish a limit to overlapping based on administrative cost of implementing overlap and shapes of cost functions. The critical role of the administrative cost (of coordinating overlaps) is also borne out by the model.     

Contract and product quality in platform selling

More and more e-tailers (platforms) are allowing manufacturers direct access to customers. Two common contracts are offered by platforms to manufacturers: the revenue sharing contract where a platform appropriates a portion of the manufacturer’s revenue, and the fixed fee contract where a platform charges a fixed rent for each sale. Using an analytical model, this paper studies the interrelationship between a platform’s contract choice and a manufacturer’s product quality decision. We find that if product quality is exogenously given, the platform will always adopt the revenue sharing contract. If the manufacturer endogenously decides the quality, however, the platform’s contract choice may be changed. This is because the revenue sharing contract, compared to fixed fee, leads to a lower selling price of the manufacturer, whereas the fixed fee contract can motivate a higher quality than does revenue sharing. As a result, a large (small) market heterogeneity induces the platform to adopt the revenue sharing (fixed fee) contract. We also extend the model to several directions, finding that longer product line, manufacturer competition, lower marginal production cost, and higher platform cost all tend to induce the platform to put forward a fixed fee contract; while if quality decision is less flexible than contract decision, the platform is more ready to embrace revenue sharing. Besides, when there are two platforms competing for the same market, they should differentiate their contract choices so as to mitigate competition.     

Optimal core acquisition and remanufacturing policies under uncertain core quality fractions

Cores acquired by a remanufacturer are typically highly variable in quality. Even if the expected fractions of the various quality levels are known, then the exact fractions when acquiring cores are still uncertain. Our model incorporates this uncertainty in determining optimal acquisition decisions by considering multiple quality classes and a multinomial quality distribution for an acquired lot. We derive optimal acquisition and remanufacturing policies for both deterministic and uncertain demand. For deterministic demand, we derive a simple closed-form expression for the total expected cost. In a numerical experiment, we highlight the effect of uncertainty in quality fractions on the optimal number of acquired cores and show that the cost error of ignoring uncertainty can be significant. For uncertain demand, we derive optimal newsboy-type solutions for the optimal remanufacture-up-to levels and an approximate expression for the total expected cost given the number of acquired cores. In a further numerical experiment, we explore the effects of demand uncertainty on the optimal acquisition and remanufacturing decisions, and on the total expected cost.     

An agent-based investigation into the new product development capability

The capability to bring products to market which comply with quality, cost and development time goals is vital to the survival of firms in a competitve environment. New product development comprises knowledge creation and search and can be organized in different ways. In this paper, we study the performance of several alternative organizational models for new product development using a model of distributed, self-adapting (learning) agents. The agents (a marketing and a production agent) are modelled via neural networks. The artificial new product development process analyzed starts with learning on the basis of an initial set of production and marketing data about possible products and their evaluation. Subsequently, in each step of the process, the agents search for a better product with their current models of the environment and, then, refine their representations based on additional prototypes generated (new learning data). Within this framework, we investigate the influence of different types of new product search methods and generating prototypes/learning according to the performance of individual agents and the organization as a whole. In particular, sequential, team-based Trial & Error and House of Quality guided search are combined with prototype sampling methods of different intensity and breadth; also, the complexity of the agents (number of hidden units) is varied. It turns out that both the knowledge base and the search procedure have a significant impact on the agents' generalization ability and success in new product development. Andreas Mild was born in Vienna, Austria, in 1973. He studied business administration in Vienna, in 2000 he received his Ph.D. from the Vienna University of Economics and Business Administration (WU). Since 2003 he is associated professor at the WU. He has been guest professor in Frankfurt, Germany, Sydney, Australia and Bangkok, Thailand. Previous research appeared in Journals such as MIS Quarterly, Management Science and Marketing Science. His research interests currently include agent-based models, new product development and recommender systems. Alfred Taudes was born in Vienna, Austria, in 1959. He studied business administration and management information systems (MIS) in Vienna (doctorate 1984), in 1991 he received his Ph.D. from the Vienna University of Economics and Business Administration (WU). He was assistant professor at the WU (1986–1991) and professor for MIS at the German Universities of Augsburg (1991), Münster (1991/92) and Essen (1992/93). Since 1993, he has been professor for MIS at the WU and Head of the Department for Production Management. Since 2000, Dr. Taudes has been speaker for the Special Research Area SFB # 010 (Adaptive Information Systems and Modelling in Economics and Management Science). His research interests currently include agent-based models of industry structures, management of innovation, technology management and business strategy.     

Organizing product releases in time-driven development processes: a probabilistic analysis

In this paper, the problem is addressed of how to organizea new product development process that is fast on the one handand that provides good-quality results on the other hand. Severalplanning techniques, like PERT and CPM, are available to analysethe completion time or product release time of such complexprocesses. Although these techniques are all well known andare widely used in project management, they do not address theiterative mode of operation that is characteristic for suchuncertain processes. Neither do they offer a tool or guidelinesto ‘design’ a composition of iterative processesbecause they are analytical. In this paper, a quantitative concept is presented for modellingthe release time of a single uncertain iterative activity, asa random variable to deal with the probabilistic aspect in asimple way. From this simple model, the complexity is extendedsystematically to model fundamentally different configurations,that are on the one hand simple enough to be studied analyticallyand on the other hand exhibit their fundamentally differentrelease characteristics, as experienced in real life. From theanalysis, guidelines are formulated for organizing or (re)configuringa complex process configuration. It is demonstrated that organizing uncertain processes fora fast product release requires a balance between the exploitationof the principles of concurrent engineering and the risk ofoverrunning time targets. An important factor in this balanceis the decision structure for the release of intermediate results.The ‘empowerment’ structure, a structure where decisionsare not clustered as milestones but are made without any delay,offers great opportunity in terms of small mean release timesand small variances thereof.     

A dynamic model for optimal design quality and return policies

A clearly explained and generous return policy has been established as a competitive weapon to enhance sales. From the firm’s point of view, a generous return policy will increase sales revenue, but will also increase cost due to increased likelihood of return. Design quality of the product has been used as a competitive weapon for a long time. This paper recognizes the relationship between design quality and price of the product, and the firm’s return policy. Quality level in the product would influence the amount of return directly. When the product quality is higher, the customer satisfaction rate will increase and the probability of return will decrease. We develop a profit-maximization model to jointly obtain optimal policies for the product quality level, price and the return policy over time. The model presented in this paper is dynamic in nature and considers the decisions as the product moves through the life cycle. We obtain a number of managerial guidelines for using marketing and operational strategy variables to obtain the maximum benefit from the market. We mention several future research possibilities.     

Single firm product diffusion model for single-function and fusion products

The prosperity of multifunction products (also referred to as fusion products) has changed the landscape of the marketplace for several electronics products. To illustrate, as fusion products gain popularity in cellular phones and office machines, we observe that single-function products (e.g., stand-alone PDAs and stand-alone scanners) gradually disappear from the market as they are supplanted by fusion products. This paper presents a product diffusion model that captures the diffusion transition from two distinct single-function products into one fusion product. We investigate the optimal launch time of the fusion product under various conditions and conduct a numerical analysis to demonstrate the dynamics among the three products. Similar to previous multi-generation single product diffusion models, we find that the planning horizon, the products’ relative profit margin, and substitution effects are important to the launch time decision. However, there are several unique factors that warrant special consideration when a firm introduces a fusion product to the market: the firm’s competitive role, buyer consolidation of purchases to a multi-function product, the fusion technology and the age of current single-function products.     

Decision development in facilitated modelling workshops

While the facilitated modelling literature recognises the importance of the group process within facilitated modelling workshops, published empirical research rarely examines their dynamic nature. In this paper, we address this gap in the literature in two ways. First, we propose to locate facilitated modelling workshops as the main focus of investigation, and adopt decision development as the analytical lens. Second, we provide guidance regarding how to implement a research strategy that is informed by such a focus. We start by mapping the different conceptualisations of decision development that seem embedded within the facilitated modelling tradition, and contrast them with theoretical models from the group communication field. Our analysis identifies a number of potentially useful areas for the study of facilitated modelling workshops from a decision development perspective, and articulates a number tentative research questions and testable propositions amenable to empirical research. Central to our proposal are research methods for the study of dynamic group processes. We thus discuss the steps required to extract group process data from facilitated modelling workshops that are usable and open to analysis. This includes a review of issues regarding research design, coding scheme development, data coding and choice of analytical techniques. Finally, we offer conclusions and briefly discuss some feasibility issues related to the implementation of our proposal.     

Alternative supply chain production-sales policies for new product diffusion: An agent-based modeling and simulation approach

Applying agent-based modeling and simulation (ABMS) methodology, this paper analyzes the impact of alternative production-sales policies on the diffusion of a new generic product and the generated NPV of profit. The key features of the ABMS model, that captures the marketplace as a complex adaptive system, are: (i) supply chain capacity is constrained; (ii) consumers’ new product adoption decisions are influenced by marketing activities as well as positive and negative word-of-mouth (WOM) between consumers; (iii) interactions among consumers taking place in the context of their social network are captured at the individual level; and (iv) the new product adoption process is adaptive. Conducting over 1 million simulation experiments, we determined the “best” production-sales policies under various parameter combinations based on the NPV of profit generated over the diffusion process. The key findings are as follows: (1) on average, the build-up policy with delayed marketing is the preferred policy in the case of only positive WOM as well as the case of positive and negative WOM. This policy provides the highest expected NPV of profit on average and it also performs very smoothly with respect to changes in build-up periods. (2) It is critical to consider the significant impact of negative word-of-mouth in choosing production-sales policies. Neglecting the effect of negative word-of-mouth can lead to poor policy recommendations, incorrect conclusions concerning the impact of operational parameters on the policy choice, and suboptimal choice of build-up periods.     

On routing in VLSI design and communication networks

In this paper, we study the global routing problem in VLSI design and the multicast routing problem in communication networks. First we propose new and realistic models for both problems. In the global routing problem in VLSI design, we are given a lattice graph and subsets of the vertex set. The goal is to generate trees spanning these vertices in the subsets to minimize a linear combination of overall wirelength (edge length) and the number of bends of trees with respect to edge capacity constraints. In the multicast routing problem in communication networks, a graph is given to represent the network, together with subsets of the vertex set. We are required to find trees to span the given subsets and the overall edge length is minimized with respect to capacity constraints. Both problems are APX-hard. We present the integer linear programming (LP) formulation of both problems and solve the LP relaxations by the fast approximation algorithms for min-max resource-sharing problems in [K. Jansen, H. Zhang, Approximation algorithms for general packing problems and their application to the multicast congestion problem, Math. Programming, to appear, doi:10.1007/s10107-007-0106-8] (which is a generalization of the approximation algorithm proposed by Grigoriadis and Khachiyan [Coordination complexity of parallel price-directive decomposition, Math. Oper. Res. 2 (1996) 321-340]). For the global routing problem, we investigate the particular property of lattice graphs and propose a combinatorial technique to overcome the hardness due to the bend-dependent vertex cost. Finally, we develop asymptotic approximation algorithms for both problems with ratios depending on the best known approximation ratio for the minimum Steiner tree problem. They are the first known theoretical approximation bound results for the problems of minimizing the total costs (including both the edge and the bend costs) while spanning all given subsets of vertices.     

Modelling imperfect advance demand information and analysis of optimal inventory policies

We consider an inventory control problem where it is possible to collect some imperfect information on future demand. We refer to such information as imperfect Advance Demand Information (ADI), which may occur in different forms of applications. A simple example is a company that uses sales representatives to market its products, in which case the collection of sales representatives’ information as to the number of customers interested in a product can generate an indication about the future sales of that product, hence it constitutes imperfect ADI. Other applications include internet retailing, Vendor Managed Inventory (VMI) applications and Collaborative Planning, Forecasting, and Replenishment (CPFR) environments. We develop a model that incorporates imperfect ADI with ordering decisions. Under our system settings, we show that the optimal policy is of order-up-to type, where the order level is a function of imperfect ADI. We also provide some characterizations of the optimal solution. We develop an expression for the expected cost benefits of imperfect ADI for the myopic problem. Our analytical and empirical findings reveal the conditions under which imperfect ADI is more valuable.     

Production and availability policies through the Markov Decision Process and myopic methods for contractual and selective orders

In this paper, we consider a supply chain with one manufacturer, one retailer, and some online customers. In addition to supplying the retailer, manufacturers may selectively take orders from individuals online. Through the Markov Decision Process, we explore the optimal production and availability policy for a manufacturer to determine whether to produce one more unit of products and whether to indicate “in stock” or “out of stock” on website. We measure the benefits and influences of adding online customers with and without the retailer’s inventory information sharing. We also simulate the production and availability policy via a myopic method, which can be implemented easily in the real world. Prediction of simple switching functions for the production and availability is proposed. We find the information sharing, production capacity and unit profit from online orders are the primary factors influencing manufacturer profits and optimal policy. The manufacturer might reserve 50% production capacity for contractual orders from the retailer and devote the remaining capacity to selective orders from spontaneous online customers.     

Buffer sizing in multi-product multi-reactor batch processes: Impact of allocation and campaign sizing policies

This paper studies the impact of management policies, such as product allocation and campaign sizing, on the required size of the finished goods inventories in a multi-product multi-reactor batch process. Demand, setup and batch processing times for these products are assumed to be stochastic, and the inventory buffer for every product type needs to be such that target customer service levels are met. To perform this analysis, we develop a queueing model that allows us to explicitly estimate service levels as a function of the buffer size, and the allocation/campaign sizing policies. This model can be used to evaluate the service level given an existing buffer configuration, as well as to determine the buffer sizes required across products to meet a pre-specified service level. It also allows us to formulate a number of insights into how product allocation decisions and campaign planning policies affect buffer sizing decisions in symmetric production systems.