TY - JOUR
T1 - Strategic workforce and project planning for engineering automotive production systems
T2 - tackling the transition to electric vehicles
AU - Kolter, Maximilian
AU - Grunow, Martin
AU - Kolisch, Rainer
AU - Stäblein, Thomas
N1 - Publisher Copyright:
© 2024 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.
PY - 2024
Y1 - 2024
N2 - Car manufacturers are electrifying their product portfolios as a reaction to restrictions imposed on car emissions. This leads to additional product introductions of battery electric vehicles to the existing portfolio of internal combustion engine vehicles. For each introduction, car manufacturers must engineer the corresponding production systems. The engineering of these production systems is executed as projects that consist of designing, building, installing, and testing, requiring different types of engineers. Car manufacturers deploy an engineering workforce and outsource work to engineering service providers. In practice, workforce planning, project planning, and outsourcing are performed sequentially using spreadsheets. However, portfolio electrification increases the complexity of planning, calling for more advanced methods. We formulate an integrated workforce and project planning problem (mixed-integer programme) to minimise outsourcing and perform an experimental study using realistic data representing different prevalent strategies for portfolio electrification. Our approach significantly reduces outsourcing and increases workforce utilisation compared to current industry practice for a wide range of workforce sizes. Furthermore, we investigate the benefit of partially aligning the current practice with our integrated approach. Optimising outsourcing alone while maintaining the sequential planning process reaps 70% to 80% of the potential benefits, and integrating workforce or project planning achieves up to 90%.
AB - Car manufacturers are electrifying their product portfolios as a reaction to restrictions imposed on car emissions. This leads to additional product introductions of battery electric vehicles to the existing portfolio of internal combustion engine vehicles. For each introduction, car manufacturers must engineer the corresponding production systems. The engineering of these production systems is executed as projects that consist of designing, building, installing, and testing, requiring different types of engineers. Car manufacturers deploy an engineering workforce and outsource work to engineering service providers. In practice, workforce planning, project planning, and outsourcing are performed sequentially using spreadsheets. However, portfolio electrification increases the complexity of planning, calling for more advanced methods. We formulate an integrated workforce and project planning problem (mixed-integer programme) to minimise outsourcing and perform an experimental study using realistic data representing different prevalent strategies for portfolio electrification. Our approach significantly reduces outsourcing and increases workforce utilisation compared to current industry practice for a wide range of workforce sizes. Furthermore, we investigate the benefit of partially aligning the current practice with our integrated approach. Optimising outsourcing alone while maintaining the sequential planning process reaps 70% to 80% of the potential benefits, and integrating workforce or project planning achieves up to 90%.
KW - Automotive industry
KW - mixed-integer programming
KW - production systems
KW - project scheduling
KW - workforce planning
UR - http://www.scopus.com/inward/record.url?scp=85198327529&partnerID=8YFLogxK
U2 - 10.1080/00207543.2024.2371097
DO - 10.1080/00207543.2024.2371097
M3 - Article
AN - SCOPUS:85198327529
SN - 0020-7543
JO - International Journal of Production Research
JF - International Journal of Production Research
ER -