Tag: build to order
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The quality connection
Recently I wrote about quality rankings for automotive manufacturers and the perception of these rankings in the market. While the marketing teams at these companies must shoulder the burden to convince consumers about their products’ quality, there is a very real connection between product quality and configuration management.
In many industries where products have grown over time with constant additions of new features and flexibility to allow customers to build to order, the level of complexity is staggering. Often the number of configurations sold on an annual basis is surprisingly close to the total units sold for that same period. This “snowflake” situation is one of the worst possible scenarios in product complexity as each unit has its own signature. Obviously, the production of these products also requires flexibility in manufacturing. This may result in reduced use of automation, and often it leads to units being reconfigured where components installed during one step are either removed or modified in a later step due to a unique situation.
These one-off manufacturing processes open the door for product quality issues due to fewer controls during production. Put simply, if I can reduce the number of different things that must be done during production I should be able to do those things better.
So product management teams have direct input on product quality via product complexity. Managing the product option mix to reduce the overall number of configurations can promote the increased quality that all manufacturers are looking for.
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How many choice combinations does your product have? That depends.
Possible combinations
This is a question with several answers. The easiest answer is the least useful. The number of possible build combinations, or unique configurations, is easily computed by multiplying the number of options for each feature. For example, if your product has feature A with 3 options, feature B with 2 options and feature C with 4 options, then there are 24 (3 x 2 x 4) possible build combinations.
These numbers grow very rapidly. If you have 5 features, each with 4 options, there are about 1,000 build combinations (exactly 1,024). With 10 such features, the number of combinations is about 1 million (1,048,576), and with 15 features it is over 1 billion (1,073,741,824).
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8 more definitions you need to know for product complexity analysis
1. Kit
A kit is a collection of parts that are used together for some purpose — for example, all the parts needed to implement air conditioning on a particular model of a car. A kit is assigned its own part number.
2. BOM
BOM stands for bill of materials. When a customer makes a selection of choices chooses a configuration (i.e., makes a complete set of option choices), the manufacturer translates the order into a collection of parts that are needed to assemble it. The BOM is expressed in terms of part numbers. These part numbers may refer to whole kits, composite parts or specific atomic parts. A complete vehicle, or washing machine, will contain many parts that the customer has not chosen. But these parts appear in every instance, or else they are implied by the combination of choices that the customer made.
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