How do Produktvarianten really cost much?

Photo: I&R concept consultation (openPR) - market situation
The times as Henry Ford „you can each color still announced have, so long it is black “is for a long time past. Customers demand individual products, which correspond exactly to their requirements. At the same time it is expected that the products become more efficient and more economical.

Emergence of variant costs
Do you know the genuine expenditures for Produktvarianten The complexity costs in such a way specified are malicious, because they arise creeping. With each product change the costs increase „a little “more. They distribute themselves over all ranges in the own enterprise and on the suppliers. Begun of the development, over examination, release, job planning, arrangement, purchase, logistics, quality assurance up to production with tooling expenses, preparation times and handling, in order to call only some.

Variant expenditures in the detail to seize is pedantic and laborious. They are therefore usually charged over overhead costs, which cannot be cause-fairly assigned. Transparency over the emergence of the expenditures is lost with increasing number of variants gradually. Frequently the prices for new Produktvarianten with empirical values are computed: „We calculated special purpose machines with 200% impact. There we are certainly on the safe side. “The real costs of variants with all associated expenditures exceed the calculated costs frequently substantially. Then the high costs of special productions eat the profits of standard products.

Practical example
Let us a practical example regard. A manufacturer for high-quality domestic appliances manufactures 4 million devices in the year. Each year scarcely 2000 new Produktvarianten are developed and produced. The spectrum reaches from a simple color variant over Design variants with new plastic housings up to extensive technical variants with new controls. The task consisted of in detail seizing and cause-fairly assigning the expenditures for Produktvarianten in the enterprise.

To determine in more than 10 of year old project practice with target engineering a structured proceeding developed around complexity costs, describes Uwe butcher. First the Produktvarianten are systematically seized, evaluated and classified. Also technical and market-relevant connections are to consider as well as restrictions. Devices for the American market are offered for example only with certain technical equipments and security characteristics.

With the next step the expenditures in the individual divisions are analyzed. In structured interviews the expenditures on working plane are seized, quantified and deposited in a data base. The data in the interviews can deviate partially strongly from the real expenditure. By Konsistenzprüfungen and plausibility checks the correction of the data takes place. The corrected values are discussed and co-ordinated with the responsible persons. „After a correction loop very exact information about the variant expenditures lies forwards “, describes Uwe butcher.

Undreamt-of starting points for optimization
The systematic collection of the variant-specific expenditures opens undreamt-of possibilities for the optimization. From the determined cost drivers directly recommendations for action for the entire process chain can be derived. So for example concrete references to the lowering of the preparation times, to the reduction of test and qualification costs or for the lowering of manufacturing costs with the supplier.
The Potenziale is still larger with the development of new products. If admits the variant-specific expenditures are, the complexity costs can be simulated over all series away first and lowered so systematically. Here often undreamt-of Potenziale lies fallow.

I&R concept consultation
Station route 40
85567 Grafing with Munich
Mrs. Marianne fire
Tel. 08092 8533660
Mail mbrand@irman.de
www.irman.de

The I&R concept consultation is a highly specialized engineer and Managementdienstleister with the emphasis:
- Lowering of manufacturing costs with complex products
- Development of innovative product solutions
- Reduction of the expenditures for Produktvarianten
Among the clientele today middle and large enterprises from equipment construction, automobile industry, industry producing capital goods, electro-technology, among them airbus, AUDI, Krauss Maffei Wegmann or Siemens rank.

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