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It-driven reorganization of order processing in small batch railway vehicle production

Objective



The rail vehicle industry is subject to a strong increase in customer requirements concerning delivery service, quality and pricing as well as part of a global concentration process. In this situation, new and strong competitors, mostly from Asia, are threatening traditional European companies by intensively bidding for the classical European clientele. To survive this selection process, European rail vehicle manufacturers need to shift from the existing function oriented organisation to a highly flexible organisation, focused on customer demands and business processes and share their work within European company networks. This urgent need for improvement requires a radical, sector representative change management. Since the existing function oriented organisation in conjunction with function oriented Information Technology (IT) has established a deadlock it can only be resolved through fundamental changes concerning company organisation, IT and human resources. The overall objective of IT-REOP is to transform the traditional rail vehicle production enterprise into a highly flexible, dynamic organism characterised by streamlined customer oriented business processes, advanced process oriented IT and highly motivated employees. In such a manufacturing system, drastic reductions of lead times, increased productivity and quality, and improved customer services for stand-alone or networked companies are envisaged.

The conceptual framework of IT-REOP aims at improving competitiveness of European rail vehicle manufacturers by transforming good business practice in the framework of organisation, IT and human resources to world wide best practice taking advantage of existing Business Process Reengineering methodologies. To achieve this best practice, the industrial end-users have set the following objectives:
- Lead time reduction by 50 % (from 36 down to 18 months for the delivery of a first wagon),
- Reduction of adjustment time from an average 100,000 down to 40,000 hours,
- Reduction of numbers of newly developed pieces from 17,000 down to 10,000,
- Increased use of standardised pieces from 5 % to 10 % and
- Increase the export quota outside the European Community by 50 %.

To achieve these objectives, the methods of Business Process Reengineering (BPR) as well as Simultaneous Engineering have to be adapted and applied. An integrated demand processing and project management system will be introduced and multifunctional team structures are to be established.

The layout of IT-REOP is structured along the three mainstreams:
- Business Process Reengineering,
- Information Technology, and
- Human Resources while concentrating on analysis and requirement definition tasks.

The results of this project will provide an integrated method to systematically derive an enterprise status quo for organisational structures, IT and human resources. Thus bilding an optimal information and requirement basis for reengineering projects to be carried out. Tools for objective analysis and requirement definitions will be developed and the results will be published in a generalised way. They shall be adopted in the entire industrial sector of rail vehicle manufacturing. The industrial companies intend to exploit the results for further internal use as well as to perform a transfer to existing networks of suppliers and customers on an European level. The participants within this project will exploit the result for multisectorial application and perform a transfer to a large European clientele.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Waggonfabrik Talbot
Address
Juelicher Strasse 213-237
52070 Aachen
Germany

Participants (3)

Bombardier-Wien Schienenfahrzeuge
Austria
Address
Donaufelderstrasse 73-79
1210 Wien
Forschungsinstitut fuer Rationalisierung
Germany
Address
Pontdriesch 14/46
52062 Aachen
Intra - Unternehmensberatung
Germany
Address
Konigsallee 60B
40212 Dusseldorf