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An integrated BPMS framework for automotive part development

Article in Journal of Advanced Manufacturing Systems · June 2004

DOI: 10.1142/S0219686704000387

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April 19, 2004 21:19 WSPC/180-JAMS 00038

Journal of Advanced Manufacturing Systems

Vol. 3, No. 1 (2004) 33–51

c World Scientific Publishing Company

AN INTEGRATED BPMS FRAMEWORK FOR AUTOMOTIVE

PART DEVELOPMENT

BYOUNG K. CHOI∗ and SEOCK K. YOO†

VMS Lab, Department of Industrial Engineering, KAIST
373-1 Gusong-dong, Yusong-gu, Deajeon, 305-701, Korea
∗bkchoi@vmslab.kaist.ac.kr
†skyoo@vmslab.kaist.ac.kr

In recent years, car makers are relying more heavily on global sourcing of sup-
plies while automotive suppliers are going through a rapid global consolidation pro-
cess, which requires automotive suppliers develop parts in shorter time at lower cost
with higher quality. To meet these challenges, automotive suppliers need a well-
established information system strategy together with a BPMS (business process man-
agement system) framework tailored to them. In this paper, a workflow-based BPMS
framework for automotive part development is proposed together with an informa-
tion system strategy. Component technologies for developing such a BPMS are avail-
able, but the gap is in methodologies for developing it. This paper aims to fill
this gap.

Keywords: Business process management system; workflow; automotive supplier;

product development process; system integration.

1. Introduction
In recent years, car makers are relying more heavily on global sourcing of supplies
while reducing the number of their first tier suppliers. The number of first tier
suppliers is expected to reduce to about 3,500 worldwide in the year 2010 from
about 30,000 in 1988, while the global automotive part market is to be tripled
during the same period, from about 3,000 hundred million US dollars in 1990 to
about 9,000 hundred million US dollars in 2010.7 As a result, automotive suppliers
are going through a rapid global consolidation process.
Accompanied by this global consolidation process are a number of key changes
in automotive industry: (1) The role of suppliers is changing from part maker to
module maker; (2) The OEM-supplier relationship is changing from direct control
with “guest engineering” to responsibility delegation with collaborative engineering;
(3) The product creation process is more heavily involved in virtual engineering.
All this changes push the automotive suppliers harder to develop parts in shorter
time at lower cost with higher quality.8

33
April 19, 2004 21:19 WSPC/180-JAMS 00038

34 B. K. Choi & S. K. Yoo

To meet these challenges, automotive suppliers are employing a variety of IT

solutions such as PDM (product data management) systems, PLM (product lifecy-
cle management) tools, ERP (enterprise resource planning) systems, and groupware
solutions. The authors have been working closely with a major automotive supplier
in Korea and learned that the company was confused with the conflicting promises
of different IT solutions. What they need most is an integrated BPMS (business pro-
cess management system) framework, together with a well-established information
system strategy tailored to automotive suppliers. There have been proposed a num-
ber of approaches in the literature regarding BPMS framework. Perhaps, the three
most relevant ones are the metal-model approach,11 common-database approach,13
and workflow-based approach.5
First, based on a general model for the automotive part development activities,
a meta-model consisting of three objects and eight diagrams is presented in the
literature.9 The three objects of the meta-model are Subject (actors), Activity and
Information. The diagrams are grouped into three categories: (1) Diagrams rep-
resenting relationships within the objects; (2) Diagrams representing relationships
between the objects; (3) Diagrams for activity schedule and information seman-
tics. The meta-model may be a valuable tool for preparing and introducing PDM
systems.11 Second, web-based integrated information system (common database)
architecture for automobile components design and manufacturing is presented in
the literature.13 For the development of automotive components, various designers,
developers and manufacturing personnel are involved, each group needing different
application systems. The proposed architecture is a web-based integrated informa-
tion system in which CAD system, standard part library, and technical database
are integrated by common database.
The third approach is a workflow-based BPMS that can provide and support5 :
(1) A way of going directly from a visualization of what needs to be done to a sys-
tem for doing it; (2) A platform for sharing business processes among systems,
people and partners; (3) The ability to change processes in use and in design
smoothly; (4) Processes that can evolve and maintain their state; (5) Processes
whose designs embed business intelligence to capture such events as sudden changes
in customer preferences. Thus, it can provide a systematic framework for the
administrative and scheduling systems supporting the automotive part develop-
ment process.
Presented in this paper is a workflow-based integrated BPMS framework for
automotive part development, in which the overall development process is super-
vised by a supervisory-control workflow system and each “group” of individual
activities controlled by a respective execution-control workflow system. The paper is
organized as follows: A brief review of product development processes in automotive
industry is provided in Sec. 2, and a BPMS framework is proposed in Sec. 3, together
with workflow models for supervisory control and execution control. Implementa-
tion considerations are elaborated in Sec. 4, followed by brief concluding remarks
in the final section.
April 19, 2004 21:19 WSPC/180-JAMS 00038

An Integrated BPMS Framework for Automotive Part Development 35

2. Automotive Product Development Processes

2.1. R&D activities in the automotive industry
Industrial R&D (research and development) processes are involved in a contin-
uous technology flow starting from scientific investigation and experimentation,
through innovative exploitation and engineering, to manufacturing.2 In practice,
the entire R&D life cycle is divided into three phases: (1) R&D phase for science-
based research and technical innovation; (2) NPD (new product development)
phase for new platform development; and (3) PD (product development) for an
improved product in the same platform.15
Key players in automotive industry are the OEM (car makers), part suppliers
and material suppliers. As indicated in Fig. 1, the OEM and the material suppli-
ers are involved in all the three phases of R&D, while the part suppliers mostly
engaged in NPD and PD phases. A typical first tier automotive supplier may have
300 engineers in the PD division (technical marketing, product design, process
development, tooling, and pilot production) while about 40 engineers are in the
NPD division.

2.2. Automotive product development process

In QS9000, the development life-cycle for a new car is represented in a PQP (prod-
uct quality planning) timing chart,1 where the entire cycle is divided into five over-
lapping phases: Planning, Product D&D (design and development), Process D&D,
Product and process validation, and Production. As shown in Fig. 2, defined in
the timing chart are five milestone points: (1) Concept initiation and approval;
(2) Program approval at the end of the Planning phase; (3) Prototype point at the
end of the Product D&D phase; (4) Pilot point at the end of the Process D&D;
(5) Launch point at the end of Product and process validation.

OEM
Parts Materials
Requirements
Part
Suppliers Material
Materials Supplier

OEM R&D NPD PD

Part
NPD PD
Supplier

Martial
Supplier R&D NPD PD

Fig. 1. R&D activities in automotive industry.

April 19, 2004 21:19 WSPC/180-JAMS 00038

36 B. K. Choi & S. K. Yoo

Concept Program Prototype Pilot Launch

Initiation/Approval Approval

planning

product design & dev.

process design & development

product & process validation

validation

production

Plan & Define Product design & Process design & Product & Feedback
program development development process assessment &
verification verification validation Corrective action

Fig. 2. Product quality planning timing chart in QS9000.

In practice, the PQP timing chart for a new car development is unfolded into
a detailed product development milestone chart in which major milestone points
are planned along a time axis. Shown in Fig. 3 is a typical milestone chart for a
new car to be put on the market in 24 months (counting from the model freeze
point). In the OEM, the development process starts with the new material & tech-
nology confirm and ends at M 2 (second mass production confirm). Major mile-
stones in between are Model approval, Model freeze, Proto-drawing release, first
and second Prototype builds, T 1 (1st try-out), P 1 (1st pilot production), T 2, P 2,
and M 1.
The OEM’s milestones dictate the part supplier’s product development pro-
cesses. To be competitive, a supplier must demonstrate its ability to keep the mile-
stones while meeting the OEM demands of the lowest possible price with the highest
possible quality. These capabilities along with a short lead-time to quote are cru-
cial in order to increase the chance of closing a deal (Estimated closing rates for
international bidding are less than 20%). Once the order is secured, the supplier
has to meet the OEM’s milestone schedule until the ISIR (initial sample inspection
report) approval point. As indicated in Fig. 3, the supplier’s product development
process can be decomposed into four phases: Product design, Process development,
Tooling, and Pilot-production.
 New material &
Model Model Produ ction
technology Proto DWG Master DWG release
confirm approval freeze release Vehicle
1st pr
prot
oto.
o. 2nd pr
prot
oto.
o.
build
bu build
bu P- 1 P- 2
M+0 M+5 M+7
M+17 M+20
Produ
Produ ction
on

OEM T1 T2 M1 M2
M+15 M+18.5 M+21 M+23 M+24
April 19, 2004 21:19 WSPC/180-JAMS

Produ ct Develop Req. Proto DWG Initial produ ction Final prod uction ISIR
Conce pt order. spec. appr oval DWG approval DWG appr oval Approval

(M-4) (M+5)
00038

Feasibility Dev. Plan Proto DWG Proto part Production DWG Pilot part ISIR Part
study Report
Planni
Pl nning
ng

Fe bility
Feasibi y Prot
Pr ot o Bu ild
d &
Part Prot
Protoo de
design
gn Produ
Produ ction
on De
Design
gn.
stud
st udy Test
Te
Maker
Process
Pr ss De
Develop
op
* ISIR : Initial Sample Inspection Report
* P-0: Initial Pilot Production
Tooling
To ng

P-0 P-1 Pre

Pre Product
Pr uct ion
on

Fig. 3. Product development milestone chart.

An Integrated BPMS Framework for Automotive Part Development
37
April 19, 2004 21:19 WSPC/180-JAMS 00038

38 B. K. Choi & S. K. Yoo

3. BPMS Framework for Automotive Part Development

The automotive part supplier has to manage its product development process to
meet OEM’s demands optimally with the highest possible quality at the lowest
possible price. Notice that the supplier has one milestone chart (Fig. 3) to follow
for each secured order. Thus, a typical first tier supplier may be managing a few
dozens of milestone charts in a given time. In addition, it has to manage a consid-
erable number of feasibility studies for future bidding. Thus, in order to manage
its product development process effectively, the supplier needs a systematic BPMS
framework.
The BPMS framework should be positioned within the information system strat-
egy of the company. A starting point for establishing an information system strat-
egy for automotive suppliers may be the ARIS architecture4 in which five layers
of information systems are identified: (1) Long term planning and decision sys-
tems; (2) Analysis and information systems; (3) Reporting and controlling systems;
(4) Value-added job accounting systems; (5) Quantity-oriented operative systems.
The two layers at the top are often called SEM (strategic enterprise management),
and the fourth layer is better known as ERP. In the fifth layer are administrative
and scheduling systems for product design, manufacturing (spanning from process
design to pilot production), purchasing, production, sales, etc. Even though core
competences of automotive suppliers lie at the product development (i.e. product
design and manufacturing) phase in this last layer, no systematic frameworks for the
administrative and scheduling systems are available. Shown in Fig. 4 is a framework
of information system strategy for automotive suppliers in which the third wave of
BPM (denoted as an Integrated BPM System) is located at the bottom layer of the
ARIS architecture.

3.1. Integrated BPMS framework for product development

We want to develop a BPMS framework for automotive part development based
on the Product Development Milestone Chart given in Fig. 3. The first step is to
construct a Process Chain Diagram3 reflecting the milestone chart. Shown in Fig. 5
is a rough Process Chain Diagram for the product development processes of an
automotive supplier in Korea, where the development process is initiated by IRFD
(initial request for development) and terminated at the approval of ISIR (initial
sample inspection report).
As depicted in Fig. 5, individual activities are grouped into two types: supervi-
sory control activities and execution activities. In practice, execution activities are
handled by a number of separate departments, thus they may be grouped further
into (1) Product design activities; (2) Process development activities; (3) Tooling
activities; and (4) Pilot production activities. With this decomposition of activi-
ties, each group of activities may be handled by a separate workflow (management)
system.14 In our case, there are five workflow systems — one SCW (supervisory
control workflow) system and four execution-control workflow systems.
April 19, 2004 21:19 WSPC/180-JAMS 00038

An Integrated BPMS Framework for Automotive Part Development 39

Strategic planning & DSS

SEM

Reporting and Controlling system

Core competence
area Value-oriented job accounting systems

ERP
{Sales, Purchasing, Production, Accounting, …}

Quantity-oriented operative systems

Integrated BPM System

Personal
Design Manufacturing Production Placement
(Process Dev. Tooling, Pilot)

CAD/CAE PDM CAM POP/DAS

SEM : Strategic Enterprise Management

Fig. 4. Information system strategy for automotive suppliers.

Shown in Fig. 6 is an integrated BPMS framework proposed in the paper. It

has a hierarchical structure in which the SCW system controls the four execution-
control workflow systems: Product Design Workflow, Process Development Work-
flow, Tooling Workflow and Pilot Production Workflow. Once the order is secured,
communications among the workflow systems may be as follows: (1) The SCW sends
a Design order to the Product Design Workflow together with Requirements specs
and Layout; (2) After the design of the part, the Product Design Workflow sends a
Design approval request to SCW, and when the design is approved, it releases Prod-
uct drawing to the Process Development Workflow and Tooling Workflow; (3) The
SCW system releases a process Development order to the Process Development
Workflow together with Production requirements; and so on.
It should be noted that the Integrated BPMS Framework given in Fig. 6 is just
a “framework” in the sense that its actual configurations may vary according to
the organizational structure of the company. (The one given in the figure is based
on the organizational structure of a Korean automotive part supplier the authors
are working with.) The salient feature of the proposed framework, however, is its
hierarchical structure consisting of a SCW (supervisory control workflow) system
and a number of execution control workflow systems.
 40

Proto Product ion ISIR

IRFD Select Suppl ier Release DWG App Approval
OEM
Product Design Prot o DWG Product ion DWG Product ion App.
Concept
Order & Spec.

Project Proto Order Proto Production ISIR Approval Production

IRFD Review FS Report
Register Release Evaluation Order Release Request Approval
B. K. Choi & S. K. Yoo

Project
Planning Supervi
Su viso
sory
y Co
Control
ol Pr
Proc
oc ess
April 19, 2004 21:19 WSPC/180-JAMS

ISIR
Feasibility Proto Prot o Product ion
Study Design Build & Test Design

Pa
Part Prod
Product Design
De gn Pr
Proc
oc ess Process
Pr ss De
Develop
op Pr
Proces
cess
Proces s
00038

Ma
Maker Design

FS: feasibility study

IRFD: initial request for development Jig & fixture
Installation
Development
ISIR : Initial Sample Inspection Repor t
Mold
Design Pilot
Pi ot Pr
Prod.
od. Pr
Proces
cess
Mold
Manufacturing Try-out

Pilot
Tooling
To ng Pr
Proc
oc ess product ion

Fig. 5. Process chain diagram for the entire part development process.
 Design order
Requirement spec. & layout

Product Design Workflow Su

Supervi
viso
sory
y Co
Control
ol Wo
Workf
kflow
ow
Design app. request
ACT1
AC ACT2
AC ACT3
AC ? ACT5
AC ACT3
ACT1 ACT2 ACT5
ACT4
AC Design approval ACT4

Produ ct DWG Develop. Production

order requirements
April 19, 2004 21:19 WSPC/180-JAMS

Tooling order C/ F
Process Develop.Workflow Inspect .
ACT1
AC ACT2
AC ACT3
AC ? ACT5
AC Production ISIR
order
00038

ACT4
AC

Tooling Workflow
Jig & Fixture DWG ACT2
AC
ACT1
AC ACT3
AC ? ACT5
AC
Product DWG
ACT4
AC

Data flow
Installation spec Pilot Production Workflow
Control flow
Production spec. ACT1
AC ACT2
AC ACT3
AC ? ACT5
AC

ACT4
AC

Fig. 6. Integrated BPMS framework for part development.

An Integrated BPMS Framework for Automotive Part Development
41
April 19, 2004 21:19 WSPC/180-JAMS 00038

42 B. K. Choi & S. K. Yoo

3.2. Execution control workflow systems

In this section, a brief description of how to construct a workflow model for an exe-
cution control workflow system will be presented. PCD (Process Chain Diagram)4
found to be an effective tool for modeling product development processes. Shown
in Fig. 7 is a PCD for the Product Design Workflow. As shown in the figure, there
are five types of entities in the PCD: Event, Activity, Document, CAD Model, and
Application (software system or actor).
Upon receiving a FS (feasibility study) Order from the Supervisory Control
Workflow system, Feasibility Study is carried out based on the Product Concept
specified by the OEM. After a Review Meeting, FS Report is compiled and dis-
tributed. Then, it waits for Proto Design Order to make Project Registration at
Enovia VPM (a PDM system). Once the project is launched, the Product Design
Workflow goes through Design Planning, Structure Design, and so on, until the
Proto Drawing is released and stored in the PDM system database.
At the aggregate level, product design activities may be grouped into four types
as illustrated in Fig. 8 — technical information processing activity, geometric infor-
mation processing activity, collaborative work, and wait. By using the activity
icons given in Fig. 8, a workflow model for the Product Design Workflow given
by Fig. 7 may be described as shown in Fig. 9. The workflow model of Fig. 9 was
obtained by using a commercial workflow management system.6 Workflow mod-
els for other execution-control workflow systems (Process Development Workflow,
Tooling Workflow, and Pilot Production Workflow) may be obtained similarly.

3.3. Supervisory control workflow system

A workflow model for the SCW (supervisory control workflow) system may also
be obtained by following the steps described above. That is, (1) a Process Chain
Diagram is constructed; (2) activity types are identified; and (3) a workflow model
is constructed using a workflow management system. As shown in Fig. 10, four
activity types are identified for the SCW system: Receive, Dispatch, Make-Decision
and Wait. Once completed, the workflow model for the SCW system would look
like the one shown in Fig. 11.

4. Implementation Considerations
As mentioned earlier, the authors have been working with a major Korean auto-
motive supplier to formulate an information system strategy (see Fig. 1) for the
company together with a BPMS framework (see Fig. 6) for its product develop-
ment process. In order to realize the Integrated BPMS Framework described in
the previous section, a number of practical questions have to be answered. How to
accommodate the application software systems (IT solutions and tools) the com-
pany is currently using or is planning to introduce? How to handle the quality
 FS Order
Event
Ev
Fe bility
Feasibi Re ew
Review Distribu
Dist bute
stud
st udy Meeting
Me ng rep
eport Activi
Ac vity

Product FS Docum
cum ent
Concept Report
CAD Model
CA Mo

Prot o Design Requirement

Order Specs
April 19, 2004 21:19 WSPC/180-JAMS

Proj
Projec
ect Design
De gn St uctur
Struc ure Review
Re ew
DFMEA
DF
Regist
Re stratation
on Pl nning
Planni ng Design
De gn Me ng
Meeting
00038

Release Lay-out Structure DFMEA

Plan mode l DWG sheet

Enov
Enovia
a VP
VPM

La -out
Lay-out Detai
De ail Design
De gn Proto
Prot o DW
DWG
Design
De gn Design
De gn Re ew
Review Releas
Re ease

Lay-out Proto part EO Docum ent

DWG DWG VPM DB
(EBOM)

CATIA
CA A V4 Prot o
DWG
Plotter
An Integrated BPMS Framework for Automotive Part Development

Fig. 7. Process chain diagram for the product design workflow.

43
April 19, 2004 21:19 WSPC/180-JAMS 00038

44 B. K. Choi & S. K. Yoo

Type
Ty Descript
De ption
on Example
Ex

Technical inf. Technical information processing

processing with documents (manually) or
using appl ication programs Feasibility study Design planning

Geometric Geometric information processing

inf. and data generation using CAx
processing systems or manually Lay-out design Detail design

Collaborative Communication and co llaboration

work with OEM and/ or internal divisions
DFMEA Review meeting

Wait Wait for next event

Wait

Fig. 8. Activity types in the product design workflow.

system requirements under the BPMS environment? How to migrate from the cur-
rent “off-line” business processes to the BPMS-based business processes?

4.1. Application software systems integration

Automotive suppliers use various types of application software: (1) CAD, PDM,
CAE systems for product design; (2) CAD systems, Viewers, VFS (virtual factory
simulators) for process development; (3) CAD, RP (rapid prototyping), CAM, CAE
systems for tooling; (4) Inspection systems, simulation tools, MES (manufacturing
execution systems) for pilot production. A salient feature of workflow manage-
ment systems is that these applications (i.e. application software systems) can be
directly interfaced with the workflow engine.14 Thus, the proposed BPMS frame-
work would have 3-Layers Architecture as depicted in Fig. 12 — the Supervisory
Control Workflow at the center, the Execution Control Workflows in the middle,
and the Applications at the periphery.

4.2. Quality system requirements

Automotive suppliers are required to meet ISO9001-based QS (quality system)
requirements, like QS9000 (recently QS9000 is being replaced by ISO/TS16949),
as well as OEM-specific requirements. The goal for QS9000 is the development of
fundamental quality systems that provide for continuous improvement, emphasizing
defect prevention and the reduction of variation and waste in the supply chain.10
These QS requirements play an important role for the suppliers to improve quality,
April 19, 2004 21:19 WSPC/180-JAMS 00038

An Integrated BPMS Framework for Automotive Part Development 45

Workflow model for the product design workflow.

Fig. 9.
Modeled with Bizflow ® process designer
April 19, 2004 21:19 WSPC/180-JAMS 00038

46 B. K. Choi & S. K. Yoo

Type Description Example

Receive Get information from OEM or

internal clients and check-in
Get design app. Get ISIR

Select participants and release

Dispatch
orders
Proto-design order Proto-build order Project registration

General information processing

Make decision
and managing
Project planning Meeting / review

Wait Wait for next event

Wait

Fig. 10. Activity types in the supervisory control workflow.

but generating and maintaining all the documents required for the verification of
conformance to these QS requirements are not an easy task.
Thus, the BPM system for product development is required to handle the QS
requirements. In the case of QS9000, input documents for product development
are Voice of Customer, Business Plan, Benchmark Data, Product Reliability Study,
etc. It is the responsibility of the Supervisory Control Workflow to generate a set
of documents (Design Goals, Quality Goals, etc.) for the Product Design Workflow
which in turn generates a set of documents such as DFMEA (design failure mode
and effects analysis), DFM/DFA (design for manufacturing/assembly), Design Ver-
ification, and Design Review. Thus, the BPMS framework of Fig. 6 will have Core-
Shell Architecture as shown in Fig. 13 — the “best-practice” execution processes
are handled at the core, and the QS requirements are managed at the shell.

4.3. Migration issues

How to migrate from the current “off-line” business processes to the BPMS-based
business processes? As mentioned earlier in Sec. 2, a typical global first tier supplier
may have 40 engineers engaged in NPD (new product development) and about 300
engineers in product development. Among the 300 engineers, 10 engineers are in
technical marketing, 200 in product design, 15 in process development, 50 in tooling
(including mold shop), and 15 in pilot production. Thus, the integrated BPMS
framework of Fig. 6 cannot be implemented and put into operation at once.
A sequence of implementing the integrated BPMS would be to (1) introduce a
BPM system at the NPD division so that the company can get used to the new
method of managing their business processes; (2) introduce the Supervisory Control
Workflow; (3) introduce the Product Design Workflow while connecting it to the
April 19, 2004 21:19 WSPC/180-JAMS 00038

An Integrated BPMS Framework for Automotive Part Development 47

Workflow model for the supervisory control workflow.

Fig. 11.
Modeled with Bizflow ® process designer
April 19, 2004 21:19 WSPC/180-JAMS 00038

48 B. K. Choi & S. K. Yoo

CAD PDM CAE Viewer CAD VFS

Product Design Process Develop

ACT1 ACT2 ACT3 ? ACT4 ACT1 ACT2 ACT3 ? ACT4

ACT5 ACT5

Supervisory Control
ACT3
ACT1 ACT2 ACT5
ACT4

Execution Control
Pilot Production Tooling
ACT1 ACT2 ACT3 ? ACT4 ACT1 ACT2 ACT3 ? ACT4
ACT5 ACT5

Inspection Simulation MES RP CAE

CAM
Applications

Fig. 12. 3-layers architecture for application integration.

Supervisory Control Workflow, and so on. This is the scenario the authors are
following in implementing the proposed BPMS at a Korean automotive supplier.
Currently, a BPM system running on a commercial workflow engine, which took
about six months to develop, is in use at the NPD division since early this year,12
and the Supervisory Control Workflow is on the drawing board.

5. Conclusions and Discussions

Component technologies for developing such a BPMS are available, but the gap is
in methodologies for developing it. This paper aims to fill this gap even though
the proposed framework has not been fully validated. While working with industry
people, the authors experienced that overcoming organizational barriers (or resis-
tances to change) was a more difficult part of the story. However, once this gap
is filled and the barriers overcome, which we believe are possible, the Integrated
BPMS proposed in the paper would play a central role in attaining competitive
advantages as depicted in Fig. 14. As a final note, the proposed BPMS framework
is based on a centralized information system paradigm. However, for an extended
enterprise environment in which product design, process development, tooling and
production process are carried out by different partners along the supply chain, a
 Voice
Vo ce of Cu
Custom
omer
Bu
Busine
ness Pl
Plan
an
Benchm
chmarkk Da
Data
Pr
Product
uct Re
Reliab
ability
y St
Stud
udies
es

Me
Meas. Sy
Sys. Evaluat
Ev uation
on
Supe rvi sor y Cont rol De gn Go
Design Goals
Pre
Pre Pr
Proc
oc . Ca
Cap. Stud
Study
Quality
Qu y Go Goals
Prod
Prod. Pa
Part Ap
Approv
oval ACT3
ACT1 ACT2 ACT5 Product
Pr uct As
Assur Plan
an
Pr
Prod
od. Va
Valida
dation
on Te
Test
ACT4 Pre-
Pre- BOM
Prod
Prod. Co
Control
ol Pl
Plan
an
April 19, 2004 21:19 WSPC/180-JAMS

Pilot Production Product

Pr oduct Design
Design
ACT1
ACT1 ACT2
ACT2 ACT3
ACT3 ?
? ACT5
ACT5 ACT1 ACT2
ACT2 ACT3 ACT5
ACT1 ACT3 ? ACT5

ACT4
ACT4 ACT4
ACT4
00038

Best Practice Execution Processes

DF
DFMEA, DFM/
DF DFDFA
Pr
Process
ss Fl
Flow
ow Ch
Chart ProcesesDevelop
Processs Develop Tooling Design
De gn
Floo
Floor Pl
Plan
an La
Layout
ACT1
ACT1 ACT2
ACT2 ACT3
ACT3 ? ACT5
ACT5 ACT1
ACT1 ACT2
ACT2 ACT3
ACT3 ? ACT5
ACT5 Verifica
Ve cation
on
PFMEA
PF
ACT4
Design
De gn Re
Review
ew
Co
Control
ol Pl
Plan
an ACT4 ACT4
ACT4
Prot
Protot
otyp
ype Build
Bu
Process
Pr ss Ins
nstruct
uct ion
on
Engineer
En eering ng Sp
Spec

QS9000 Requirements
An Integrated BPMS Framework for Automotive Part Development

Fig. 13. Core-Shell Architecture for QS requirements handling.

49
April 19, 2004 21:19 WSPC/180-JAMS 00038

50 B. K. Choi & S. K. Yoo

Procurement Management Information System Fulfillme

Fu ment
B2B (ERP/SCM ) B2
B2B
•Accurate/Real-time
Information

Collaboration
Integrated BPMS Collaboration

Product Process
Suppliers R&D Dev. Dev. Tooling Pilot OEM

Responsiveness, Transparency,Teaming • CTP

• Prod. Inf. sharing QS9000/ISO16949 • ECO/ECR
• ECO/ECR control • Traceability
• Schedule control • Application integration • What-if Sim.
• Contents sharing

Engineering Application Systems

Material/Part PDM/CAD/CAM/CAE/CAI Product

• ECO/ECR: engineering change order/ request

• CTP: capable-to-promise

Fig. 14. Competitive advantages through integrated BPMS.

“modular” framework based on the concept of “listener pattern”3 may become a

better choice. In this framework, individual workflow systems are encapsulated and
linked together in a modular manner.

Acknowledgement
The Ministry of Science & Technology of Korea supported the research through a
“National Lab” grant.

References
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An Integrated BPMS Framework for Automotive Part Development 51

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