Complexity Management
- core Element of complex
Product Architectures
John Deere Live Report
Frank Bürschgens
Bietigheim-Bissingen, September 2010
John Deere History
1837 – John Deere develops the
first self scouring steel plow
1918 – John Deere enters the
tractor business
1927 – John Deere sells its first
combines
1956 – John Deere „goes
abroad“
1963 – John Deere starts to sell
lawn & groundscare products
2
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Agriculture and Turf
Global Operating Model (GOM)
5 Global External Platforms –
A platform consists of a portfolio of ‘like’ product lines
Crop
Harvesting
Turf and
Utility
Hay and
Forage
Crop Care
Tractors
Combines
Utility Vehicles
Seeding
Front-End
Equipment
Riding Lawn
Equipment
Self-Propelled
Forage
Harvesters
Large
(7000, 8000,
9000)
Cane
Commercial
Mowing
Heads
Golf
Mowing
Cotton
Walk-Behind
Mowers
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Balers
Tillage
Application
Equipment
Medium
(6000)
Utility
(2000, 3000,
4000, 5000)
Loaders
John Deere Werke Mannheim (D)
John Deere‘s largest asset
outside North America
– 1.5 mil tractors produced since
1921
– Production 2009: 32,100 units
– Represents 2/3rds of the German
tractor production
– Products: 5M/5R/6030-/7030-
Series
– 70 – 200 hp
– 2,900 Employees
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External and internal megatrends have a
significant influence on the JD business
External megatrends
• Increasing population
• Environmental
• Diversification of the markets/global
markets
• New technologies: E-vehicles and
mechatronics
• Shorter innovation and technology
lifecycles
• Solutions provider (IMET)
Internal megatrends
• GOM:
• Product lines
• Internal + external platforms
• ..
• Design anywhere build anywhere (DABA):
global R&D and productions networks
• …
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| Complexity Management | September2010
Agrar-ManagementSystem (AMS)
AutoTrac
iTEC Pro
ISOBUS
JDLink
Field Doc
Mid-Tractor: Product Architecture Organization
Complexity
Management
Variety and Cost:
- Avoidance
- Reduction
- Managing
Evaluation through the
whole value chain
Strategic component
planning
Focus of presentation
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Product Specification
Product requirement
Design specification
PDP changes
Required vs. realized
features
Product Definition/
Engineering Configuration
Generic modular
product structure
PDP-projects
CH
Chassis
DT
D riv e
Tra in
OS
Op era tor
S ta tio n
HY
Hy dra ul ics
RI
Re ar
Imp l.
EN
E ng in e
EA
En gi ne
A u xil ia ry
AA
Tr actor
gen era l
FA
Fro nt A xl e
FI
Fr on t
I mpl .
RA
R ear Ax le
Components +
configuration
Preparation of
customer configuration
Overview of the status quo and current activities
of the complexity management
CH
Chassis
DT
Drive
Train
OS
Operator
Station
HY
Hydraulics
RI
Rear
Im pl.
EN
Eng ine
EA
Engine
Auxiliary
AA
Tractor
general
FA
Front Axle
FI
Front
Impl.
RA
Rear Axle
• Based on the pilot projects: roll-out of the
complexity management
• Training of the method and the supporting tool
• Application for identified main modules
existing “building
block” structure
18,00%
16,00%
TIC percentage
14,00%
12,00%
• Further development of the method: module
roadmap for lifecycle variety planning
10,00%
8,00%
6,00%
• Complexity cockpit chart
4,00%
2,00%
0,00%
0
20
40
60
80
100
number of ETN (variants) per SFC (Design center view)
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120
• Guideline for generic modular product structure
(building block)
The easy and scalable application of the feature
tree is the first step to implement complexity
management fast
2. managing complexity/
defining scenarios
1. Application of the feature tree
A
A
Open CM
w/ Citrix
Define variety
drivers
B
Set-up rules &
feature tree
C
B
C
Define volume
and costs
D
D
Pareto and option
analysis
E
E
E
Possible scenarios:
• Bundling/ packaging
• Standardization/
modularization
• Interface management
• “Roadmapping”/ lifecycle
• Substitution of variants
• Just in sequence
• Variant creation point
• …
C
• Fast application for one person or small group (engineer,
marketing)
• Flexible application on different structure levels (single part,
module, product) à scalable introduction
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• Cross functional team
• Project specific
Different variety impact along the value chain
Market planning
ProductSpecs and variety planning
# variants
Waterloo
DesignCenter
Mannheim
DesignCenter
interfactory
Waterloo
factory
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Mannheim
factory
Further integration of Complexity Management
CI
PDP
phase 1
phase 2
Complx.
Targets
Complexity
Mgmt.
Feature tree
first draft
phase 3
optimized
feature tree
Prod. Specs
Multi-project coordination/support/controlling
Project
Mgmt.
First specifications/
feature infos
Design
Groups
Set-up initial, current
global Feature Tree
Product
Planning
Set-up/optimize global Feature
Tree for „main“Modules
Set-up
Detail Spec
Set-up Tractor ProdSpecs
Config.
Set-up Configuration
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…
The application of the feature tree achieves
several benefits along the whole value chain
• Overview of variety/complexity on
different levels (part, module, product)
• Common understanding of variety along
the value chain
• Fast simulation of different optimization
scenarios
• Fast option analysis
• Pareto analysis of the variants à fast
identification of “low hanging fruits”
• Easy cost comparison of options
• Early planning of modules/parts/
products without part numbers
• Easy application/ learning of the tool
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Complexity Management is a success story for
Mannheim
„Tue G
utes u
nd red
e d ar
über ! “
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Thank you very much for your attention!
Frank Bürschgens
Manager Product Architecture
Mid Tractor Platform
John Deere Werke Mannheim
Zweigniederlassung der Deere & Company
John-Deere-Str. 90 • 68163 Mannheim • Germany
phone: +49 621 829-5735
mailto: BuerschgensFrank@JohnDeere.com
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