Challenges in the Fuzzy Front End of the Production Development Process

Abstract

As the demand for customized products increases, manufacturing industries are forced to adapt to rapid changing requirements in product demand by continuously developing new innovative and changeable production systems. In the early phases of production development, there are uncertainty aspects that needs to be managed until freeze of product design and development of a suitable production system. This front end is commonly considered as fuzzy since there is a lack of a structured production development process that supports the uncertain and iterative work that is required to develop feasible production systems in early phases. By identifying these challenges in the fuzzy front end of production development it is possible to inhibit future disturbances in the rest of the process and to increase future production system performance. In the literature, challenges in the latter part of the production development process has been thoroughly examined. However, few empirical investigations have explored the fuzzy front end in production development. The purpose of this study is to investigate challenges in the fuzzy front end of the production development process, focusing on new or comprehensive production system changes. To study these challenges, a multiple case study with 4 cases has been conducted. The empirical investigation consists of 5 semi-structured interviews and 5 participant observations. The findings show multiple challenges closely connected to project pre-conditions and organization structure related factors. Various project uncertainties in this early phase entails challenges to determine valid project objectives, scope and KPIs. Moreover, estimating the right amount of time and resources needed. Complex organization structures may have a significant influence on the way of working resulting in slowness in decision making. Furthermore, various communication challenges are identified which are mainly connected with the incapacity of including all stakeholders early in the development process.