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Springer awards “BestMasters” to the best application-oriented master’s theses, which were completed at renowned chairs of economic sciences in Germany, Austria, and Switzerland in 2013.Th e works received highest marks and were recommended for publication bysupervisors. As a rule, they show a high degree of application orientation and dealwith current issues from diff erent fi elds of economics.Th e series addresses practitioners as well as scientists and off ers guidance for earlystage researchers.
Anna-Lena Jäger
Global Purchasing Processes in the Business Sector Automotive Aftermarket
Development of a Reference Model
Forewords by Prof. Dr.-Ing. Jürgen Gottschalck and Dipl.Ing. Jochen Polke
Anna-Lena JägerPforzheim, Germany
ISBN 978-3-658-04647-7 ISBN 978-3-658-04648-4 (eBook)DOI 10.1007/978-3-658-04648-4
Th e Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografi e; detailed bibliographic data are available in the Internet at http://dnb.d-nb.de.
Library of Congress Control Number: 2013956639
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Foreword V
Foreword
The present work connects in an exemplary manner methodical approaches to a practical
problem formulation and provides a crucial solution in the end. Through this, it was possible
to begin the implementation of the compiled suggestions in a contemporary way at the Robert
Bosch GmbH. Exactly this is the aim of the education in the course of studies Business Ad-
ministration and Engineering at the University of Applied Science Pforzheim.
Prof. Dr.-Ing. Jürgen Gottschalck Professor for Purchasing and Logistic at the University of Applied Science Pforzheim
Foreword VII
Foreword
"Processes make slow”, “processes interfere, cost time and resources". These or similar
statements can be heard often when processes should be implemented new or reworked; and it
may be even right partially if there are no guidelines or every business unit only did what and
how they wanted to. However, if an enterprise or a functional area reaches a certain size, sev-
eral locations are to be led in different countries or even regions, processes are more than es-
sential. The savings of resources and time by avoiding iterations, the "do it right at the first
time", balance from experience each additional effort.
The business division Automotive Aftermarket of the Robert Bosch GmbH, and with it also
the purchasing area, has grown enormously in recent years. Especially purchasing plays a
crucial importance with its strategic significance and responsibility regarding cost-quality-
logistic. Today a considerably three-digit number of employees deal in almost three dozen
locations worldwide with purchasing subjects and purchasing quality management. Supplier
A delivers product B in region C and product D in region E; the product group F is purchased
from supplier G from region H for the regions I and J. These and similar complex relations in
a worldwide operating, transnational and vertical function are only controllable successfully
with standardized and globally consistent processes which are at the same time „lean, fast and
focused“.
The present thesis describes the approach as well as the results of the modification of existing
purchasing processes and accordingly the development and implementation of new guidelines
and standards; the suitable process development was very challenging and both criteria - the
process design as well as with the innovative aspect - were realized.
The real attractiveness of the work was that the subject was not a theoretical issue. The entire
purchasing process map is implemented worldwide and for the first time more than 20,000
employees in a business division are affected and act integrative within their daily operations
by using the new guidelines and standards.
Dipl.Ing. Jochen Polke Director Purchasing Quality Management Automotive Aftermarket, Robert Bosch GmbH
Acknowledgement IX
Acknowledgement
The present master thesis was written from March to September 2013 in the business sector
Automotive Aftermarket at the Robert Bosch GmbH in Karlsruhe in the Purchasing Quality
Management Department. Due to the purchase of many companies in recent years and a still
growing Automotive Aftermarket business sector, it was moreover indicated that a reorgani-
zation of the Process Map is unavoidable. It became clear that it was the only way to satisfy
the new complex process requirements in future as well as to coping with the new challenges.
Hence, the subject arose from suggestions by the Purchasing Quality Management Depart-
ment and the importance and implementation was confirmed by the management. The goal of
the master thesis is accordingly the development of a reference model for all purchasing pro-
cesses in the Automotive Aftermarket area.
I thank the Robert Bosch GmbH for the possibility to write the thesis in the enterprise. More-
over, I thank all employees of the involved Purchasing Departments for their active support
by the realization of the master thesis. In addition, I would like to thank particularly for the
extensive support and the professional assistance on the part of the enterprise Mr. Thomas
Wald, Mr. Jochen Polke as well as the whole team of my department.
I owe thanks to Prof. Dr. Jürgen Gottschalck for the extraordinary support and comprehensive
scientific supervision of the work by the University of Pforzheim. Furthermore I would like to
thank Dipl. Phys. Bernd Kuppinger for the second correction.
Finally I would like to thank all people who have supported me by the realization of my mas-
ter thesis as well as throughout my whole studies. These special thanks are valid above all for
my family and my friends.
Anna-Lena Jäger
List of Contents XI
List of Contents
List of Figures ........................................................................................................................ XV
List of Abbreviations ......................................................................................................... XVII
1 Introduction ....................................................................................................................... 1
1.1 Problem ........................................................................................................................ 1
1.2 Goals and Limitations .................................................................................................. 2
1.3 Structure and Contents................................................................................................. 3
2 Company Profile ............................................................................................................... 6
2.1 Robert Bosch GmbH ................................................................................................... 6
2.2 Business Sector Automotive Aftermarket ................................................................... 7
2.3 Organization Structure of AA/PU ............................................................................... 8
3 Theoretical Backgrounds ............................................................................................... 10
3.1 Business Process Management .................................................................................. 10
3.1.1 Definition ........................................................................................................... 10
3.1.2 Importance and Duties of Business Process Management ................................. 13
3.1.3 Business Process Management Loop ................................................................. 14
3.1.4 Different Approaches in Practice ....................................................................... 16
3.2 Business Modeling .................................................................................................... 17
4 Approach of the survey and modeling of processes ..................................................... 19
4.1 Preparation for the Process Analysis ......................................................................... 19
4.1.1 Principles according Modeling Rules ................................................................ 19
4.1.1.1 Intention of the principles ............................................................................... 19
4.1.1.2 Description of the single principles ................................................................ 20
4.1.2 Definition of general conditions ......................................................................... 21
4.1.2.1 Setting of a Framework .................................................................................. 21
4.1.2.2 Description and Selection of Survey Methods ............................................... 22
4.1.3 Procedure for the Process Modeling .................................................................. 24
4.1.3.1 Definition of the Modeling Purpose ............................................................... 24
XII List of Contents
4.1.3.2 Determination of Rules for the Modeling Purpose ......................................... 25
4.1.3.3 Definition of Modeling Language and Modeling Tool .................................. 26
4.2 Analysis of the initial situation .................................................................................. 28
4.3 Approach with the creation of the new processes ..................................................... 29
4.4 Implementation of the new processes ........................................................................ 32
5 Process Modeling with BPMN ....................................................................................... 35
5.1 The BPMN Language ................................................................................................ 35
5.2 Important Elements of the BPMN Language ............................................................ 36
5.2.1 Swimlanes .......................................................................................................... 36
5.2.2 Flow Objects ...................................................................................................... 37
5.2.2.1 Start and End Event ........................................................................................ 37
5.2.2.2 Activity ........................................................................................................... 37
5.2.2.3 Gateways ........................................................................................................ 38
5.2.3 Connectors .......................................................................................................... 40
5.2.3.1 Sequence Flow ................................................................................................ 40
5.2.3.2 Association ..................................................................................................... 40
5.2.4 Artifacts .............................................................................................................. 41
5.2.4.1 Data Object ..................................................................................................... 41
5.2.4.2 Data Store ....................................................................................................... 41
5.3 Modeling with inubit Suite ........................................................................................ 42
6 The Project “BPM@AA” ............................................................................................... 44
6.1 Project Description .................................................................................................... 44
6.2 Overview of the PU-Reference Model ...................................................................... 45
6.3 Optimized and Developed Processes ......................................................................... 47
6.3.1 Define and agree on RPP projects ...................................................................... 47
6.3.2 Define purchasing targets ................................................................................... 49
6.3.3 Evaluate existing parts to identify potential ....................................................... 51
6.3.4 Conduct contracting ........................................................................................... 52
6.3.5 Supplier enabling projects with suppliers .......................................................... 53
6.3.6 Release series production ................................................................................... 54
List of Contents XIII
6.3.7 Maintain supplier master data ............................................................................ 55
6.3.8 Negotiate and provide contract .......................................................................... 56
6.3.9 Define and conduct incoming inspection process .............................................. 57
6.3.10 Monitor achievement of purchasing targets ....................................................... 59
6.3.11 Monitor supplier performance via cockpit chart ................................................ 60
6.3.12 Manage complaints with suppliers ..................................................................... 61
6.3.13 Reimbursement of non-conformity costs ........................................................... 63
6.3.14 Supplier development quality ............................................................................. 64
6.3.15 Perform supplier audit ........................................................................................ 66
6.3.16 Supplier development project with suppliers ..................................................... 68
7 Conclusion and Future Prospects .................................................................................. 71
Index to Appendixes ............................................................................................................... 75
References ............................................................................................................................... 95
List of Figures XV
List of Figures
Figure 1: Structure of the thesis ................................................................................................. 4
Figure 2: All divisions in the Automotive Technology Business Sector ................................... 7
Figure 3: Organization Structure of the Purchasing Department ............................................... 8
Figure 4: Sequence of a process ............................................................................................... 10
Figure 5: Chart of a business process ....................................................................................... 11
Figure 6: Process landscape of Bosch ...................................................................................... 12
Figure 7: Reference points of BPM .......................................................................................... 13
Figure 8: BPM Loop ................................................................................................................ 14
Figure 9: Different survey methods ......................................................................................... 23
Figure 10: Level Concept ......................................................................................................... 26
Figure 11: RASIC Chart ........................................................................................................... 28
Figure 12: Pool with two lanes ................................................................................................. 36
Figure 13: Start and End Event ................................................................................................ 37
Figure 14: Activity ................................................................................................................... 37
Figure 15: Exclusive Gateway ................................................................................................. 38
Figure 16: Parallel Gateway ..................................................................................................... 39
Figure 17: Inclusive Gateway .................................................................................................. 39
Figure 18: Sequence Flow ........................................................................................................ 40
Figure 19: Association ............................................................................................................. 41
Figure 20: Data Object ............................................................................................................. 41
Figure 21: Data Store ............................................................................................................... 42
Figure 22: Different phases of the project ................................................................................ 47
List of Abbreviations XVII
List of Abbreviations
AA Automotive Aftermarket
AA/COR Automotive Aftermarket Controlling Department
AA/PU Automotive Aftermarket Purchasing
AA/PUC Automotive Aftermarket Purchasing Controlling
AA/PUR Automotive Aftermarket Purchasing of Trade Goods
AA/PUQ Automotive Aftermarket Purchasing Quality Management
AA/QM Automotive Aftermarket Quality Management
BC Braking Components
BMO Benchmark and Organization Department
BPM Business Process Management
BPMI Business Process Management Initiative
BPMN Business Process Modeling Notation
BU/FC Business Unit Controlling Department
BU/PU Business Unit Purchasing Department
CFA Function Controlling, Finance and Administration Department
COR Function Controlling Department
CP Central Purchasing
CPC Cockpit Chart
CP/PUQ Central Purchasing Quality Management Department
DG Diagnostics
FI Filter
KPI Key Performance Indicators
XVIII List of Abbreviations
LOG Function Logistic Department
LPA Lean Plant Assessment
MAG Employee Performance Review Discussion
MCR Material Cost Report
MKP Function Marketing Packaging Department
MKT Function Marketing Department
OMG Object Management Group
OPL Open Point List
PA Power Train
PDCA Plan-Do-Check-Act
PU Purchasing
PUC Function Purchasing Controlling Department
PUQ Function Purchasing Quality Management Department
PUR Function Purchasing Department
QAA Quality Assurance Agreement
QMM Quality Management and Methods Department
Regional PUR Regional Purchasing Department
RM Rotation Machines
RPP Ratio Project Planning
SP Spark Plugs
TCO Total Cost of Ownership
V-Ist Current forecast
WIRE Economic calculation