Facing interface challenges in complex product development

Abstract: The purpose of this thesis is to contribute to New Product Development-literature by expanding the analysis of the R&D-manufacturing interface in complex product development in three areas, i.e. the outsourcing of manufacturing, uncertainty and time-criticality, and field service. The thesis focuses on interface challenges and solutions which concern three questions:How does the level of outsourcing of manufacturing affect the management of the R&Dmanufacturing interface in complex product development?How does the presence of uncertainty and time-criticality affect the management of the R&Dmanufacturing interface in complex product development?How does the need to consider field service requirements affect the management of the R&Dmanufacturing interface in complex product development?The background and point of departure is the realization that there are three areas which influence the management of the important, dynamic interface between R&D and manufacturing. First, the level of outsourcing of manufacturing is increasing in many industries, which makes it even more demanding to manage the R&D-manufacturing interface in complex product development. Second, complex product development may also be characterized by uncertainty and time-criticality, and previous research indicates that these factors need to be handled differently. Third, it is increasingly important to consider not only R&D and manufacturing, but also field service requirements.The research methodology rests on a multiple case study approach where the main case used in this thesis is an extreme case in terms of uncertainty, R&D intensity and volume levels, i.e. Micronic Laser Systems.The main findings of the thesis revolve around the identification of the challenges and solutions involved in complex product development. Based on five research papers, the thesis identifies challenges associated with each of the three research questions, and all challenges identified revolve around how to identify and understand conflicting requirements, to establish an understanding of changing prerequisites and their implications, and to ensure active involvement and a certain degree of competence overlap between organizational functions (internal as well as external).The solutions identified for handling these challenges have one thing in common, namely a focus on achieving controlled responsiveness and flexibility based on an understanding of tradeoffs, interaction, and informed decision-making. These solutions differ from those prescribed in conventional product development literature which tends to focus on upfront planning techniques and how to follow plans.The findings may be of value to a variety of managers in different environments, in particular for project managers who are involved in complex product development. The main reason is that this kind of product development exhibits challenges and solutions different from those described in conventional literature on new product development, at least in cases where there is some degree of uncertainty.