FROM A FEW CRAFTSMEN TO AN INTERNATIONAL NETWORK OF ALLIANCES: BOSCH DIESEL FUEL INJECTION SYSTEMS Don E. Kash Robin N. Auger Center for Science and Technology Policy School of Public Policy George Mason University 4400 University Drive, MS 3C6 Fairfax, VA 22030-4444 [email protected] [email protected] September 2003 This research has been supported, in part, by grants from the National Science Foundation and the Center for Innovation Management Studies at North Carolina State University. The authors thank the funding organizations for their support. ABSTRACT Managers of the innovation of complex technologies have to develop strategies and policies that produce adaptive organizational networks. Studies of thirteen technologies carried out in six countries suggest that managers and policy-makers benefit from focusing on organizational networks, not single organizations. The evolution of the fuel injection technology for diesel engines initiated and repeatedly innovated since 1922 by Robert Bosch GmbH of Stuttgart, Germany is used to illustrate the policy and management adaptations necessary to carry out repeated innovations as technologies move through different innovation patterns and as they evolve from simple to complex. Special attention is given to the role of cooperative alliances in the innovation, knowledge management, and decision-making associated with the development of the diesel injection technology. Three innovation patterns are evident in this evolving story. The Transformation (firstof-a-kind) Pattern (1922 – 1927) covers the period from the initiation of work on diesel injection systems to the market introduction of the first in-line pump. The first Normal (incremental) Pattern (1927 – 1960) covers the incremental innovations of mechanical in-line fuel injection systems. The first Transition (major redesign) Pattern characterized the sixteen years between 1960 and 1976 when the distributor pump, a sophisticated mechanical system, was developed. A subsequent Normal Pattern that saw incremental innovations of the distributor pump extended into the 1980s. For two decades from 1980 to 2000 a second Transition Pattern characterized the innovation activities that produced a complex electro-mechanical injection system. A third Normal Pattern began in 2000 and continues today. Over roughly two decades between 1960 and the early 1980s, the Bosch organization evolved from a hierarchical to a network structure as it carried out innovations that converted a simple technology into a complex one. As the technology has become ever more complex, the Bosch organizational structure has grown to include a tightly linked network that ranges from suppliers to users and includes a broad range of mechanical and electronic expertise. The innovation of the injection technology today involves intimate interaction between product design and manufacturing process activities. These innovation activities manifest a process of co-evolution between a continuously adapting network of supplier and user organizations and diesel injection technology that has occurred as part of an ever-changing environment (e.g., market, public policy). 2 From A Few Craftsmen To An International Network Of Alliances: Bosch Diesel Fuel Injection Systems Introduction Organizational networks are essential to the innovation of complex technologies.1 Networks are composed of multiple organizations that include the holders of core capabilities, the suppliers of complimentary assets, and user organizations.2 Alliances are the organizational relationships, which may vary in nature and structure, used to establish critical linkages in the networks that carry out the innovation of complex technologies.3 No organization (e.g., company) acting alone has all the knowledge, skills and capabilities needed to carry out the innovation of complex technologies. Thus alliances make it possible for organizational networks to access, create, synthesize, and diffuse the diverse tacit and codified knowledge (as well as other skills and capabilities) necessary for the innovation of complex technologies. In most cases as networks become more complex, the opportunities for and the speed of innovation increase.4 This paper exemplifies two fundamental tenets of Keith Pavitt’s work: 1) to improve our understanding of the innovation process through the development and use of new conceptual frameworks or classification schemes, and 2) to improve our understanding of the management of innovation within the firm by gleaning lessons from empirical case studies. The paper is part of a larger study of thirteen technologies carried out in six countries which addresses another of Pavitt’s areas of interest: the differences among firms and countries in technological development and innovation and the determinants of those differences. We investigate the pattern of technological and organizational co-evolution5 using a case study of the innovation of A complex technology is one that cannot be understood in sufficient detail by an individual so that it can be communicated across time and distance with the precision necessary to be exactly reproduced. In contrast, a simple technology can be understood. 2 DeBresson, Chris and Fernand Amesse, “Networks of Innovators: A Review and Introduction to the Issue,” Research Policy, Vol. 20, No. 5, October 1991, pp. 363-79; Miller, Roger, “Global R&D Networks and Large-Scale Innovation: The Case of the Automobile Industry, Research Policy, Vol. 23 No. 1 January 1994, pp.27-46. 3 Teece, David J., “Competition, Cooperation, and Innovation: Organizational Arrangements for Regimes of Rapid Technological Progress,” Journal of Economic Behavior and Organization, Vol. 18, No. 1, 1992, pp.1-25. 4 Kash, Don E., Robin N. Auger and Ning Li, “Organizational Requirements for the Innovation of Complex Technologies,” in John de la Mothe and Albert N. Link, eds., Networks, Alliances and Partnerships in the Innovation Process, Boston: Kluwer, 2002, pp.165-190. 5 Mangematin, Vincent, “The Simultaneous Shaping of Organization and Technology within Cooperative Agreements,” in Rod Coombs, Albert Richards, Pier P. Saviotti, and Vivien Walsh, eds., Technological Collaboration: The Dynamics of Cooperation in Industrial Innovation, Brookfield, VT: Edward Elgar, 1996, pp. 1 3 diesel fuel injection technology carried out by Robert Bosch GmbH (Bosch).6 Bosch’s diesel fuel injection technology is, at the beginning of the 21st century, both the world’s performance standard and the world’s leader in sales. Bosch has evolved from a “workshop for precision and electrical engineering” founded in Stuttgart, Germany in 1886 to an organization with locations in over 130 countries. The company produces a wide range of automotive equipment in addition to fuel-injection technology, as well as many other technical products. Over the eight decades since Bosch initiated work on a diesel fuel injection system, the technology has evolved from a simple piston pump to multiple complex electro-mechanical subsystems that are seamlessly integrated into diesel-powered systems. As part of this evolution, the technology has become strikingly complex and sophisticated, and the organizational system that has carried out these innovations has evolved from a workshop populated by skilled craftsmen to a complex network composed of diverse organizations linked by alliances. This paper investigates: 1) three patterns of innovation and their application to Bosch diesel fuel injection technology, 2) the role of cooperative alliances in Bosch injection technology innovation, and 3) the Bosch organizational network’s knowledge management and decisionmaking. Patterns of Innovation Although each technological innovation has its own distinctive sources of knowledge and capability, innovation processes can be grouped by the existence of similar characteristics, or patterns. Rycroft and Kash have labeled three patterns: transformation (first-of-a-kind), normal (incremental), and transition (major redesign).7 Some of the most evident distinctions between the patterns are variations in the organizational structures and processes used to access and use knowledge and to make decisions. The repeated innovations of the Bosch injection technology have manifested all three patterns. An innovation occurs with the first successful introduction of 119-41; Nelson, Richard R., “The Coevolution of Technologies and Institutions,” in Richard W. England, ed., Evolutionary Concepts in Contemporary Economics, Ann Arbor, MI: University of Michigan Press, 1994, pp. 13956. 6 Kash, Don E., “Bosch Fuel Injection Systems for Diesel Engines,” School of Public Policy Working Paper 03:1, Fairfax, VA: George Mason University, June 2003. 7 Rycroft, Robert W. and Don E. Kash, The Complexity Challenge: Technological Innovation for the 21st Century, London: Pinter, 1999, pp. 179-198. 4 a technology into a market. The innovations that manifest the transformation and transition patterns fit within that set commonly identified as radical. The innovations that manifest the normal pattern are commonly identified as incremental. An overview of what has occurred with the Bosch diesel injection technology is sketched in Figure 1. The transformation innovation pattern characterizes the organizational structures and processes that produce first-of-a-kind technologies, i.e., new designs. When the first-of-a-kind technology is a complex technology, a network of organizations, including holders of core capabilities, complementary asset suppliers, and end users (customers), must be formed. Only networks such as these can provide and integrate the diverse knowledge needed for the innovation. Thus, as the transformation innovation pattern occurs, both a new network and a new technology must be designed and built, largely through a trial and error learning process. The square A in the lower left corner of Figure 1 represents the innovation of the first diesel fuel injection technology. It took Bosch five years to develop its first commercial product, the in-line pump, thus the transformation pattern characterized the period from 1922 to 1927. Bosch Innovation Trajectories Complexity • Mass production processes, flexible kits for all engine sizes • Basic diesel needs: atomization, metering, timing C – Transition to Electro-Mechanical Control o ---C x mple ---N 1980-2000 - -logy 16 -- ork- etw 16 Piezo-electric Control (2003) ch no l Te ex le imp ---S h Tec 2 1 i -- gan -Or 3 --ion zat 1930 6 EPVM (1962) 6 EPVA(1966) 7 VE (1976) 1960 1970 Unit Injector / 13 Unit Pump System (1994/95) -- 7 5 1922-27 10 11 12 Ne 1962-76 5 4 9 tw ork - C B 2 A-Pump (1953) 3 M-Pump (1957) 4 P-Pump (1962) 8 pl om 1 First In-Line Pump (1927) .--- A hno Tec og y-- 13 14 15 --- • Fuel economy, reduced emissions, size, price, integrated timing C B – Transition to Distributor Pump Technology --- • Fuel economy, direct injection, lower emissions, flexibility A – Transformation Period Performance • Systems integration and synthesis, fuel economy, emissions control, comfort, functions, pilot injection and shape of injection 8 VP-20 (1982) 9 VE-EDC (1986) P-Pump Electronic 10 Governor (1987) 14 VP-44 (1996) Common 15 Rail (1997) 11 VE-EDC/DI (1989) Innovation legend: Incremental P-pump Electronic Major 12 Timing and Fundamental Governor (1993) 1980 Time 1990 2000 2010 5 Figure 1: Bosch Diesel Fuel Injection Innovation Trajectories The transition innovation pattern characterizes the organizational structure and processes that produce major changes, i.e., redesigns, of existing generic technologies. Like the technologies, the networks that carry out transitional innovations must undergo major redesigns themselves. They must merge or integrate new core capabilities in order to create a new organizational network with all of the capabilities needed to carry out the transitional innovation of the technology. Thus the redesigned network must be able to access, create, and synthesize knowledge that did not previously exist in the network. The triangles B and C in Figure 1 represent the major redesigns that moved the injection technology from an in-line mechanical system through a series of transitional innovations that now give the Bosch network the capability to deliver a range of sophisticated electro-mechanical technologies specifically designed to fit each customer’s need. During the second Bosch transitional period, a network was developed that included advanced electronic, electrical, software, and mechanical knowledge, and this network learned how to synthesize these diverse kinds of knowledge. The normal innovation pattern characterizes the organizational structure and processes that produce improvements, i.e., incremental innovations, within an existing generic design. Incremental innovations result largely from cumulative learning within the network established to innovate the first-of-a-kind technology or a redesigned technology. Although incremental innovations require diverse knowledge and participation by various organizations such as complementary asset suppliers and end-users, in the normal innovation pattern the linkages among these network participants already exist. Thus, the network is able to generate internally most of the knowledge needed to carry out the incremental innovations. In Figure 1 normal pattern innovations are represented by circles; through 2002 Bosch diesel fuel injection technologies had experienced three periods that were characterized by normal innovation patterns. The third period began in 2000 with the network that had emerged to carry out the innovation of the electro-mechanical injection systems. Within this normal pattern the network has been able routinely to innovate designs that meet the particular niche needs of the ever more diverse diesel engine designs. During its evolution, the Bosch diesel fuel injection technology crossed a fundamental threshold as it transitioned from a simple to a complex technology. The time it took to cross the 6 simple to complex threshold involved a more than two-decade period beginning in the 1960s and continuing into the 1980s. The simple to complex change resulted from an accumulation of learning and innovations. This period witnessed a major evolution from a hierarchical organization that utilized primarily mechanical knowledge to a network organization that could, with increasing speed, synthesize diverse knowledge (e.g., mechanical, materials, electrical, electronic, and software) located in different organizations. The organizational network that was developed by the use of alliances includes the diesel division, other Bosch divisions, and many other organizations. Innovation and Cooperative Alliances At the heart of the success of the processes that have produced the Bosch fuel injection innovations has been an evolving organization with an ability to learn repeatedly. For the early years, much of the organizational learning came from: accumulating experience, the codification of that experience, and the development of theory. Thus, the learning involved both the handson (i.e., tacit) knowledge acquired by Bosch craftsmen and the growing body of codified (i.e., explicit) knowledge represented by specifications, descriptions and drawings, as well as the theory, data and processes that were being accumulated in the broader scientific/technical community. Learning was originally embodied primarily within individuals, but over time it became group knowledge, and ultimately, through alliances, organizational network knowledge. With the innovation of complex electro-mechanical systems, it was necessary to develop a capacity for intimate and rapid interaction among organizations that included, for example, process equipment makers, component suppliers, universities, the Bosch diesel organization, and injection system users. As the complexity of the Bosch technology has increased, network knowledge and capabilities have increased to meet the requirements for much more complex performance, evaluation, and analysis. Cooperative alliances were, and remain, necessary to the Bosch innovation network to be able to access, use and synthesize ever more diverse explicit and tacit knowledge. The following section discusses the role that alliances have played in the innovation of Bosch diesel fuel injection technology, and it is organized according to the innovation patterns presented in Figure 1 and discussed briefly above. 7 Transformation Pattern: Mechanical Pressurized Diesel Injection System Bosch identified the need for an injection system as a result of interactions with early developers of diesel engines, and in 1922 it purchased patents from the Swiss firm Arco-Lang as an early step in the company’s development of a pump. Bosch improved upon the patented design, and the basic demands of a diesel fuel injection system—atomization, metering, and timing—were satisfied by the in-line injection pump first introduced to the market in 1927. This, and other, early in-line pumps were “simple” mechanical technologies; the generic design involved a plunger pump that forced fuel into the combustion chambers of the engine via a hydraulically operated nozzle. Bosch used only the plunger design in its injection systems for nearly four decades; it remains in use today and is produced in large quantities by Bosch and other manufacturers. While this early licensing alliance provided codified knowledge necessary for the innovation, the initial in-line injection system was developed by Bosch personnel using “craft,” or tacit, knowledge over the course of five years of trial and error development. A small technical staff with excellent basic engineering knowledge recruited from the technical universities plus craft-based technicians, the“Ober Ingenieurs,” characterized the Bosch organization during this time. Normal Pattern: Mechanical Injection Systems From 1927 to the early 1960s, Bosch carried out repeated incremental innovations (the normal innovation pattern) of the plunger mechanical pump, resulting in three different commercially successful products: the A, M, and P pumps (see Figure 1). The incremental innovations that characterized this period resulted in the adaptations needed for engines of different sizes and performance requirements. The creation of “kits” of components and design modifications gave the in-line design significant flexibility. The knowledge developed and used in carrying out the incremental innovations was predominately empirical and tacit and was heavily derived from trial and error processes. The close informal interactions with engine manufacturers during this period drove the incremental innovation process. 8 Prior to the 1960s most of the Bosch injection systems delivered fuel to indirect injection (IDI) engines that had relatively low injection pressures (up to 300 bar). With the innovation of the P pump in 1962, injection pressures were doubled, thus it was possible to design direct injection (DI) turbo-charged diesels for commercial use.8 Having crossed this threshold, a pattern of innovation followed that continued to incrementally increase injection pressures to more than 1300 bar. The significance to Bosch of the incremental innovations that produced the P pump can be seen by looking at its production and sales. Since 1962 Bosch has produced an average of 1,000 P pumps daily, and its sales have provided much of the capital for the development of other designs. Transition Pattern: Mechanical Distributor Pump The beginning of the transitional innovation pattern that delivered a successful distributor pump occurred in 1960. Part of the stimulus for undertaking the innovation of the distributor pump was a growing belief that there was a need for a diesel engine-compatible injection system for cars with performance capabilities that could not be met and delivered by the in-line pump.9 The transition pattern encompassed a learning process that required three distinct designs (EPVM, EPVA, and VE) before major commercial success was achieved. During development of its initial commercial distributor pump, Bosch bought a French company that had developed a distributor pump of a different design. Bosch personnel worked with the French personnel to incorporate some aspects of the acquired design with its existing one to produce its second commercial distributor pump, which saw limited commercial success. The third and highly successful design that came out of the transition process was the VE pump that was selected by Volkswagen in 1976 for use in its commercially successful Golf. Among other factors, the success of the VE reflected the learning that Bosch had been accumulating as part of the development of the two preceding distributor pumps. In addition, the focus on fuel DI engines are more fuel efficient, and thus more economical than IDI engines, and are now used in most commercial vehicles and trucks. 9 The performance needs were low cost, small size, integrated timing, and a capacity to work as part of an IDI engine that had a “swirl” chamber (i.e., the smaller of the two combustion chambers had what was known as a “swirl” design). The in-line pump design could not meet these performance requirements and it specifically would not work on a swirl chamber engine. The model M in-line pump adopted by Mercedes for use in its cars in 1957 worked because its IDI engine had a patented pre-combustion chamber that worked with the in-line design. Bosch’s other customers, however, either had or were designing engines that had the swirl chamber configuration. 8 9 economy that stimulated the market for the Golf was driven by the energy crisis that began in 1973. The learning associated with the VE pump represented the beginning of a period of rapid increase in the range of technical capabilities that would be developed within what was to become a Bosch-centered organizational network. Both the nature and the speed of the innovations that were to follow would change in distinctive ways. The VE was a very different design, and it represented the integration of technical capabilities that had been developing in the years following World War II. The VE is appropriately seen as the launching of the process that saw the simple injection systems of the past become complex. Normal Pattern: Mechanical Distributor Pump The years between 1976 and 1980 involved incremental innovations of both the VE and the P pumps, plus innovations in process technology. The incremental innovations that occurred during this period did not produce any commercially successful new injection system models, but, similar to the normal pattern that followed the transformation innovation of the in-line pump, the incremental innovations that followed the introduction of the VE increased the flexibility of the distributor pump. By working closely with the diesel engine and automobile manufacturers, the VE was adapted to meet the needs of different engines and different performance requirements. There were, in all advanced countries, increasing pressures for lower exhaust emissions and increased fuel economy. It was widely accepted that DI engines offered great benefits for cars, but they could only be used if noise, emission, and comfort problems could be overcome. The experience with DI engines in the commercial engine arena was being used to respond to these emerging market demands. In summary, the normal innovation period between 1976-1980 saw a wide range of incremental innovations and the broad recognition that future innovations would have to produce injection systems that delivered higher pressures and ever more precise control. Although Bosch remained committed to its axial piston design distributor pump during this period, it did, as part of the purchase of Sigma Diesel, the French company previously mentioned, acquire a radial piston design distributor pump. Although the radial design was not the reason for the purchase, it would prove to be an asset during the next transition period. 10 Perhaps a greater asset acquired through the purchase of Sigma was the knowledge embodied in the highly educated engineers in the company. Bosch managers gave the French engineers predevelopment projects, including a high-pressure distributor pump, but a decision was made not to develop it immediately. Transition Pattern: Electro-mechanical and Complex Integration For the two decades between 1980 and 2000 the Bosch injection technology and organization was characterized by a transition innovation pattern. A review of the environment within which an organizational network developed strikes one with the magnitude of the change and the critical role flexibility and a capacity for adaptation has played. Within this context perhaps the most striking thread underlying this transition is the importance of the Bosch reputation for quality. Repeatedly, in spite of what appears from hindsight to have been a number of cases where the Bosch network was slow in making technology adaptations and carrying out redesigns, its reputation for quality saw it achieve market success. In major part the network’s record of technological success has resulted from its ability to rapidly access and synthesize new knowledge by linking to other organizations and from its openness to taking initiatives that involve the participation of many members of the network. Additionally, four external developments had major influences on the innovation process that produced the transition. These were: an increased focus on environmental protection, a need for fuel economy, rapid developments in digital electronics, and increasing consumer affluence. These developments influenced the pursuit of the knowledge needed to meet the changing performance standards. The transition occurred in two stages. The first saw redesigns of many of the injection systems that produced complex electro-mechanical systems. As part of the co-evolutionary process there was an evolution from a hierarchical organization concerned primarily with mechanical knowledge to a network that integrated a diverse range of knowledge that required accessing mechanical, electrical, electronic, and software learning. The first stage, then, was characterized by a process that was heavily involved with developing and assembling components into injection systems that are seen as distinctive subsystems of diesel engines. Central to this capability was the development of solenoid actuators. 11 The second stage began in the mid-1990s. It saw an innovation process that involved a complex synthesis that produced a nearly seamless interaction between the injection system and diesel powered cars and commercial vehicles. Only a systems integration of a very complex and sophisticated kind could provide the kind of precise and sensitive interaction between the fuel injection technology and the diesel-powered systems required to satisfy what had become exceptionally demanding performance standards. By 2000 diesel-powered systems had to meet stringent fuel economy and emission standards and do so while providing a level of comfort with regard to flexibility, noise, starting, smoothness, and acceleration that was equal to or better than what was offered by gasoline powered systems. Central to this capacity for performance was the development of high-speed solenoid valves with high levels of reliability. The introduction of electro-mechanical diesel fuel injection technology into the commercial market was characterized by the innovation of several different systems, each with distinct combinations of electrical and mechanical components (see Figure 1). The innovations during the first stage of the transition, the VP-20, VE-EDC, and VE-EDC/DI, were mechanical systems that had seen electronic control modules substituted for mechanical controls. In the latter part of the 1980s Bosch’s customers became more intimately involved in the network that carried out these innovations. For example, Volkswagen (VW) participated in the network as it was developing the VE-EDC/DI and the VW engine that used this technology entered the market in 1989, delivering a major improvement in fuel economy. To achieve what was clearly the next step it was necessary to innovate electromechanical injection systems that represented a new integrated design. Achieving the set of interrelated performance objectives that were demanded by the mid 1990s required a single electronic control system that synthesized and utilized information that included, for example, inputs from the exhaust system and transmission through to the diverse range of engine data. For these synthesized data to be used effectively the injection system had to provide a level of precise engine control that was beyond anything previously seen, plus pumps that could provide the high injection pressures needed for DI engines. By the mid 1990s digital electronics offered the capacity to collect and synthesize the diverse data required for new integrated designs and, in addition, the first versions of a control technology that provided the needed precision had been innovated. Three new designs were to 12 carry the transition to electro-mechanical injection systems to its conclusion. They were the unit injector system/unit pump system (UIS/UPS), the VP-44, and the common rail system. The UIS/UPS technology currently provides the highest injection pressures that, in conjunction with other improvements, deliver increased efficiency, considerable emissions reduction, and reduced noise. Bosch initially gained access to the UIS/UPS technology designs for commercial diesels in 1989 by purchasing a substantial interest in the U.S. firm Diesel Technology.10 European manufacturers of commercial diesels had encouraged Bosch to buy an interest in the U.S. firm. The European companies took this initiative in part because Bosch’s record of high quality manufacturing offered security that they could utilize the UIS/UPS technology with greater confidence. In similar fashion, Bosch gained access to UIS/UPS technology for auto engines with the purchase of a development group that had been created by the Austrian steel company VOEST to produce an injector system. The development group was working on a UIS/UPS design for VW, and the German auto company encouraged Bosch to gain access to this technology in part with the belief that Bosch’s manufacturing capabilities would enhance the prospects for a reliable technology. In 2002 Bosch UIS/UPS was providing high injection pressures that could be precisely controlled for both commercial and auto diesels. The combination of digital electronics, sensors, software, solenoid valves, and high pressure pumps offered a flexibility that made it possible to meet the ever increasing performance requirements. Achieving the performance requirements was possible because of the continuous innovation of both product and process technology. During this period Opal chose to make a commitment to a new diesel engine for its cars, and this was a major factor in the Bosch network undertaking the development of the VP-44. The electro-mechanical synthesis represented by the VP-44 created a complex interdependent fuel injection system. The VP-44 system features high nozzle injection pressures (above 1700 bar) and a combined pump-engine control unit that uses the latest computer technology. When the Bosch network began work on the VP-44 it was able to use the technical knowledge (specifically a radial design) it had acquired with the purchase of Sigma Diesel almost twenty years earlier by integrating a central electronic control unit into this design. The VP-44 represented an order of magnitude increase in the level of complexity when compared to Diesel Technology was owned by Penske through its ownership of Detroit Diesel, a manufacturer of commercial engines. 10 13 previous distributor systems. Innovation of the system involved the integration of knowledge, capabilities, and organizations, on a scale, and with a level of complexity, that had not previously existed. The Common Rail System (CRS) is the last of the three highly integrated injector systems innovated by Bosch in the 1990s. The unique feature of the CRS is that pressure generation and fuel injection are completely decoupled from each other. The six modules11 of the CRS are integrated, controlled, and coordinated with the engine by a single electronic control system. The CRS uses syntheses of the advances the Bosch network has made in delivering increased pressures and providing precise control to offer great flexibility to customers. The CRS offers the potential to deliver an injection system that can provide, rapidly, for the specific performance requirements of niche markets. During the early 1990s, again with the encouragement of customers, Bosch bought an Italian development group, ELASYS, from Fiat. This group had developed a CRS with the support of the Italian government. The ELASYS prototype had built on work being done for decades at a Swiss technical school. This very sophisticated system required high quality manufacturing if it was to be reliable, and this resulted in the pressure by engine producers for Bosch to make the purchase and become the manufacturer. The Bosch CRS technology was introduced to the market in 1997 for passenger cars and in 1999 for commercial vehicles. The speed with which the CRS was adopted suggests both the accelerating rate of innovation and the close relationships among the participants in the Bosch-centered organizational network. The Bosch network now has a capability to deliver specialized designs of its injection technologies for specific uses in very short periods of time. Building an Innovation Network The transition in the Bosch organization that made it possible to develop the UIS/UPS, VP-44, and CRS required the creation of a complex organizational network. It began with an expansion of the range of technical expertise in Bosch. In the late 1970s Bosch separated its diesel injection organization from the gasoline injection organization. The diesel organization The six components are: pump, pressure control valve, line leading from the pump to the accumulator, rail, line leading from the accumulator to the cylinder injector, and cylinder injector. 11 14 that was created was designated the K5 division. Shortly after its creation a change in the technical background of the leadership of K5 occurred. For roughly the first six decades of Bosch diesel injection activities people with mechanical skills and mechanical engineering knowledge led and populated the organization. The new head of K5 was an electrical engineer who had spent eight years working in the United States for Westinghouse on electronic control systems. This change in leadership reflected the belief that the future success of diesel injection systems would require the integration of electronics. In 1979 the second oil crisis focused major attention on fuel economy, resulting in increased public and governmental pressures for more efficient engines. During the same period pressures were growing for finding ways to reduce emissions. In 1980 K5 made the decision to develop electrical-electronic expertise that would lead to the development of the solenoid actuators as the route to better control. This involved the integration into the organization of not only Bosch employees with a different expertise, but it also resulted in linkages to the electronics division of Bosch that was located forty kilometers from Stuttgart, as well as to the broader electronics community. Interdisciplinary integrated project teams were created to facilitate the mixing of technological talent. The initial electronics project groups reported directly to the head of K5, and were thus organizationally parallel to the large organizational units that produced the different established injection systems, e.g., in-line and mechanical distributor. The 1980 electronics initiative is best seen as the beginning of a process of rapid organizational change that built a network of electro-mechanical organizations and knowledge with a unique capability for the synthesis of repeated electro-mechanical innovations. The network, through a process of trial and error, was able to create, access, and integrate a range of knowledge that was far beyond the capabilities of any individual. The fusion of electronics and mechanics represented the end of the era in which it was possible to believe that any individual could do a complete systems design on his own. The character of K5 and the broader organizational network changed rapidly. In 1980 electronics was foreign to the deeply embedded mechanical culture of the K5 division. A view held by some in K5 was that there was no need for major change and no need for the electromechanical design. Moreover, it was argued, a major change carried a high risk. There was not a consensus in Bosch in the early 1980s that it was necessary to take what was perceived as the high risks associated with the innovation of an electro-mechanical technology. Thus, the 15 initiatives taken and sustained within the transitional pattern required concerted leadership from top management. One part of what made the change possible is the structure of Bosch. It is a privately held corporation (today controlled by a foundation set up by the Bosch family) and has a tradition of financing its research and development initiatives from internally generated funds. The availability of an environment that tolerates long development times, plus the relatively longer development times associated with innovations in the auto and commercial vehicle industries, provided an environment that supported a transitional innovation pattern that took two decades. Central to the success of the two-decade transition was the building of an organizational network that linked, in intimate ways, suppliers of diverse capabilities at one end with diesel manufacturers at the other. Part of the capacity to access and integrate the diverse knowledge needed for the transition was the location within a hundred kilometers of Stuttgart of the key suppliers and users of an increasingly complex injection technology. Over the course of the two decades Bosch developed an organizational and personal network that shared common interests, trust, and a culture that facilitated the transitional innovation, e.g. the Swabian reputation for thrift, orderliness, and pride in workmanship. From their beginning, the Bosch fuel injection systems enjoyed continuous improvements; many of these improvements involved process innovations. Repeated improvements occurred, for example, in metallurgy, grinding, honing, and measurement techniques. Bosch people emphasize that these improvements, particularly those associated with machine tools, have been facilitated by the geographical proximity of their machine tool suppliers. High-trust personal links between Bosch and its suppliers have been invaluable, as have the links with other Bosch organizational units such as the electronics division. The history of high-trust linkages that involved more than maximizing immediate economic transactions provided a powerful reference system for adapting the mechanical organization to an electro-mechanical organizational network. The early critical relationship with the Bosch semiconductor organization illustrates what was possible. An effective relationship was developed rapidly between organizations with very different kinds of expertise. Part of the rapid capacity to develop successful cooperation with the semiconductor organizations was its close proximity (within forty kilometers of Stuttgart). Commercial success required not only quick interaction between the K5 group and the semiconductor unit, but also 16 continuous access to the rapidly changing worldwide electronics community. For example, innovation of the VP-44 required a 32-bit microprocessor. At that time only 16-bit microprocessors were commercially available from the semiconductor industry. Bosch’s ability to design and then use a merchant fabricator to manufacture its own 32-bit microprocessor required accessing the knowledge of the broader semiconductor community. Similarly, the development of control systems that could synthesize data from diverse sources to achieve desired engine performance required new computer capabilities, both hardware and software. Software that could simulate the very complex processes associated with the direct injection of high-pressure fuel was critical, and this was a whole new area of knowledge that had to be accessed and integrated into the network in the post-1980 period. Simulation made it possible to quickly design UIS/UPS and CRS for specific engines and performance patterns. Simulation was also a key factor in making the rapid development of the VP-44 possible. A high-level Bosch manager succinctly characterized the organizational and knowledge transition that was occurring in the 1980-2000 period. In his discussions with the Bosch leadership at the time of his appointment the new manager said, “The key to success would be the ability to work in teams with the disparate organizations and people who had the diverse knowledge needed for innovation.” The manager’s approach represented the route to rapid acquisition and integration of the knowledge necessary for the innovation of the ever more complex injection systems that would be developed in the last two decades of the 20th century. The manager’s language was prescient; it recognized that fuel injection systems had now moved from relatively simple mechanical systems to ever more sophisticated, ever more complex systems that required the integration of diverse kinds of knowledge at ever-greater speed with increasing flexibility. The need for speed and flexibility was to become strikingly evident in the 1990s as the pressure from customers for specialized designs of fuel injection systems became pervasive. Bosch’s customers, because they were part of the innovation network, understood that new capabilities existed and they were able to confidently demand, with short turn around times, fuel injection systems that could be orchestrated to respond to their particular engine designs and characteristics. Part of the design/sales approach of the automobile companies was to have their own unique diesel engines. The Bosch people note that as complexity increases the capacity for adaptability of design increases. Not surprisingly as the capacity for adaptability increased the 17 demand for specialized designs increased and one automobile company after another began to specialize the diesel engine models they offered their customers. Prior to 1990, the target of technical development was functionality. After that there was a change in philosophy--a change to quality, cost, and delivery (QCD, à la the Kaizen system)-and concomitantly a greater stress on teamwork. To shorten development cycles, K5 committed itself to simultaneous engineering as a way of doing business. Over the course of the 1980-2000 period the Bosch diesel injection network gave ever-greater emphasis to the development of a broad range of software capabilities. Much of the major software capability was located in Bangalore, India. As previously noted, computer simulation had become critical, but so had computer-aided design and manufacturing. These computer capabilities made it possible to move rapidly from design to manufacturing, and they speeded communication within the complex organizational network that developed over the two decades after 1980. Normal Pattern: Electromechanical Systems and Beyond By 2000 the innovations that had occurred within the transition pattern had put in place an innovation capability of major breadth and depth. The transition to electro-mechanical systems involved the development of an organizational network that can carry out the innovation of new designs on a repeated and incremental basis. The complex network that exists today has capabilities for rapid learning that represents something that is quite new; designs are now developed to meet specific engine performance requirements by what is appropriately characterized as self-organizing network. Part of the capacity for routine, incremental innovations of specialized designs for individual customers comes from the fact that Bosch has representatives co-located with its customers who deal directly with applications, thus assuring that the injection systems are seamlessly integrated into the diesel engines. These applications people, located worldwide, are key to the rapid learning of the network. They represent knowledge links in the network that can move both tacit and codified knowledge with great speed and can assist the network in adapting rapidly. The Bosch network applications function is intimately tied into the design/production activities in a way that allows the injection systems to be tuned to the precise uses and designs of the various engines. 18 The dominant characteristic of the learning organization represented by the injection system network is the growing intimacy and interaction of what is now known as the Diesel Services (DS) division (formerly K5) with its suppliers and customers. This intimate network also includes ever-closer interaction with people in universities. The need for cooperative relationships will continue to be essential for future innovation due to the external pressures of the early 21st century on this complex technology. First, there is a surplus capacity for manufacturing automobiles and, at least in the advanced countries, there is a growing market for specialized luxury products. The tendency to have relatively customized options is growing, reinforcing the need for flexibility and adaptability, and is linked to the increasing complexity of automobile systems. This pattern of adaptability is reinforced by a growing concern with environmental residuals. In addition, the rapid increase in energy costs puts additional emphasis on fuel-efficient automobiles, notably those with diesel engines. Finally, the miniaturization of technologies will undoubtedly involve rapid incremental innovations of existing diesel fuel injection systems. Knowledge Management and Decision-making12 Organizational networks are necessary in carrying out the innovation of complex technologies because networks provide the capacity to do what neither theories nor individuals can do. Networks offer a way to access and use diverse knowledge that is both codified and tacit in order to accomplish what has not been done before without an understanding of how to do it.13 Networks thus offer two critical capabilities. First, they provide a way to access, create, and use (synthesize) diverse knowledge that is located in multiple organizations and individuals. Second, they provide the structure needed for the range of people and organizations that hold the diverse knowledge to participate in decision-making.14 This section is taken from Kash, Don E., Robin N. Auger and Ning Li, “Organizational Requirements for the Innovation of Complex Technologies,” in John de la Mothe and Albert N. Link, eds., Networks, Alliances and Partnerships in the Innovation Process, Boston: Kluwer, 2002, pp.165-190. 13 Kline, Stephen J, Conceptual Foundations for Multidisciplinary Thinking, Stanford: Stanford University Press, 1995, pp. 171-8. 14 Sing, Kulwant, “The Impact of Technological Complexity and Interfirm Cooperation on Business Survival,” Academy of Management Journal, Vol 40, No. 2, April 1997, pp.339-67. 12 19 The Bosch case study provides an illustration of how knowledge management and decision-making processes occur. In addition, the case study offers insight into both the difficult adaptation associated with crossing the threshold from a simple to a complex technology and insight into the structure and processes associated with each of the three innovation patterns. A review of the knowledge needed to carry out the innovations of Bosch’s diesel fuel injection technology over the last eighty years indicates a trend toward knowledge diversity that has been accelerating at an ever more rapid rate since the 1960s. The growing diversity of knowledge has two dimensions: it includes both greater knowledge depth (e.g., a capacity for executing ever finer machining) and breadth (e.g., the inclusion of electronics into a mechanical technology). The Bosch organization’s reservoir of both codified and tacit knowledge has increased over its lifetime, and that increase has been accelerating in the last two decades. The knowledge is located in a growing number of organizations, both in other Bosch units and in organizations linked to Bosch through the diesel fuel injection network. The organizational network has developed a body of routines and heuristics15 that are essential to the successful interactions of the different organizations. The routines and heuristics exist as both codified and tacit knowledge embedded in the Bosch-centered network. A review of the decision-making associated with the injection system innovations beginning in the 1960s suggests what is increasingly a self-organizing system—a system where decision-making occurs via a process that is coordinated by consensus concerning what the performance characteristics of the new innovation will be. Further, this self-organizing system is delivering decisions ever more rapidly. This was especially evident as the network entered the new century and was manifesting the capacity to deliver specialized configurations of multiple injection system designs. The exceptions to this general pattern occurred when the decision was made to design the mechanical distributor pump in the early 1960s and again with the decision to design an electro-mechanical injection system in the early 1980s. In these instances the top management of Bosch mandated both technical and organizational changes. An illustration of the knowledge and decision-making adaptation over the last eight decades is shown in Figure 2. Box 1 in the upper left corner covers the period from 1922-1960 and reflects the fact that the knowledge needed to carry out the innovation of the in-line pumps 15 Nelson, Richard R. and Sidney G. Winter, An Evolutionary Theory of Economic Change, Cambridge, MA: Belknap Press, 1982. 20 was predominately mechanical and the decision-making was centralized in a few organizational leaders. Both the knowledge needs and the centralized decision-making during the first four decades reflected the fact that the technology was simple. The same knowledge and decisionmaking characteristics were evident in both the first-of-a-kind innovation taken to the market in 1927 and the follow-on incremental innovations. The Bosch organization was accumulating a great deal of learning both from its own internal work and from the explosion of technical knowledge that was occurring more generally. In the midst of this time period World War II drove advances in nearly every technical area, and the pattern of advancement continued in the post-war period. In summary, for this simple technology the same knowledge and decisionmaking characteristics appear in the transformation and normal innovation patterns. 19221960 Centralized Decisionmaking 1 19802000 19601976 19761980 64 2 3 4-a 19802000 4-b Diffuse 20002002 5 Less Diversity of Knowledge More Figure 2: Evolution of Knowledge and Decision-making in Bosch Network 21 Box 2 in Figure 2 refers to the period of the transitional innovation that produced the first mechanical distributor pump (1960-1976). It reflects both the use of more diverse knowledge and of less centralized decision-making. The first distributor pump design required a more sophisticated body of technical knowledge and a more diverse decision-making process. This begins the period when the injection technology began movement across a threshold from a simple to a complex technology. There is disagreement concerning whether the first distributor pump was simple or complex, but it clearly represents a major design change that was critical to the development of the complex technology represented by the electro-mechanical injection system that would be innovated later. The transition pattern ended with the commercial success of the distributor pump initially used on a large scale in the Volkswagen Golf. The period represented by Box 2 remains characterized by the use of relatively limited, primarily mechanical knowledge. It also involved relatively centralized decision-making—the design was the product of a small number of people. The mechanical distributor pump, however, represented a more sophisticated and complex technology than the previously dominant in-line pump. Box 3 in Figure 2 refers to the period after the introduction of the distributor pump in which the incremental innovations were improving both it and the in-line mechanical pump. The improvements during this period would be of major importance to the next transition, the electromechanical design. This period was characterized by an expansion of knowledge, especially an increase in depth; it involved the kind of learning commonly associated with innovations that fit the normal pattern. In summary, there was a substantial increase in the mechanical knowledge utilized, but there was not much increase in the diffusion of the decision-making over what had existed at the time of the initial innovation of the distributor pump. Boxes 4-a & b in Figure 2 represent the period when the transitional innovations were being carried out that ultimately produced the UIS/UPS, VP-44, and CRS. The period had two phases that were distinguished, among other things, by different electronic controls: solenoid actuators and solenoid valves. The period saw a very great increase in the diversity of knowledge needed. Specifically, it required integrating electronic and electrical knowledge into what quickly became an organizational network of substantial complexity. There was no longer any question about whether the injection technology was simple or complex. 22 The period reflected in Boxes 4-a & b is particularly interesting in terms of decisionmaking. Box 4-a reflects the fact that while the diversity of knowledge needed to carry out the transition innovation experienced a very large increase, at the same time there was a major movement toward centralized decision-making. Active, high level management intervention was necessary to get the self-organizing network that had been carrying out the repeated innovations of the mechanical injection systems to link with and integrate the organizations and people who held the electronic/electrical knowledge. The most significant event in this process occurred with the change in leadership of K5 from a mechanical to an electronic specialist. This major change required centralized decision-making, which involved the governing board choosing a leader who was not a “diesel person.” The new leadership then created new organizational relationships—multi-disciplinary teams that reported to the leader—that used organizational processes and management actions to integrate electronic expertise into what had been a selforganizing network composed of people with mechanical expertise. Box 4-b reflects the fact that the innovation of the electro-mechanical systems required both diverse knowledge and diffuse decision-making. The technology that was innovated during this transition pattern required the full participation of holders of diverse expertise. The complexity of the technology made the existence of a single designer impossible. Box 5 in Figure 2 represents the present period of innovation characterized by the normal pattern, by repeated incremental innovations that produce specialized configurations of the multiple injection system designs that are in current production. Incremental innovations are being carried out on four different designs. The diversity of knowledge held by the Boschcentered network makes it possible to rapidly deliver a design that fits the specific needs or desires of diverse customers. Decision-making is very diffuse and it reflects behavior that is consistent with a self-organizing network. Thus, the location of Box 5 in Figure 2 indicates that a very diverse knowledge base and a very diffuse decision-making process currently exist. The Bosch Example in a Broader Context The Bosch case study is one component of a larger study of the evolution of the innovation patterns of thirteen technologies whose organizational networks are located in six different countries. The results of these case studies suggest, as in the Bosch case, that managers 23 and policy-makers benefit from focusing on organizational networks, not single organizations. To place the Bosch example in a broader context, Figure 3 illustrates the adaptation paths traced by the knowledge and decision-making of Bosch and four other technologies studied:16 theSonyPhilips audio compact disc (CD) (Japan-Netherlands),17 the Hewlett-Packard (HP) cardioimaging technology (United States),18 the TATA Consultancy Services (TCS) software services Decision-making Centralized and products (India),19 and the Haier line of home appliances (China).20 Haier appliances HP Cardioimaging technology Diffuse Bosch fuel injection systems TCS software technology Period of Transition from Simple to Complex Technology Less Sony CD systems Diversity of Knowledge More Figure 3: Evolution of Diversity of Knowledge & Decision-making in Five Networks Kash, Don E., Robin N. Auger and Ning Li, “Organizational Requirements for the Innovation of Complex Technologies,” in John de la Mothe and Albert N. Link, eds., Networks, Alliances and Partnerships in the Innovation Process, Boston: Kluwer, 2002, pp.165-190. 17 Kash, Don E. and Robert R. Schaller, “Innovation of the Audio Compact Disc Player,” School of Public Policy Working Paper, Fairfax, VA: George Mason University, January 2000. 18 Kash, Don E., “Innovation of Cardio-Imaging Technology at Hewlett-Packard and HP/Philips,” School of Public Policy Working Paper 03:2, Fairfax, VA: George Mason University, June 2003. 19 Kash, Don E., “TATA Consultancy Services: A Case Study,” School of Public Policy Working Paper, Fairfax, VA: George Mason University, February 2003. 20 Kash, Don E., “Haier Company Innovation in Household Appliances,” School of Public Policy Working Paper, Fairfax, VA: George Mason University, November 2001. 16 24 The adaptation paths shown in Figure 3 illustrate the unique combination of knowledge and decision-making processes required for the innovation of each technology. More importantly, however, the figure shows that even for complex technologies, there are times when centralized decision-making is needed. This is particularly important when the technologies are new or experience major change, as during the transformation and transition innovation patterns (i.e., during the development of first-of-a-kind technologies and during major technology redesigns). Thus, it is during these periods that company managers need to be most actively involved. These patterns require leaders to guide and facilitate the innovation process. More broadly, it is also during these periods of substantial change that public policy makers should focus their attention and efforts. During the normal pattern, the innovation of complex technologies and simple technologies differ in their knowledge and decision-making requirements and processes. For complex technologies, incremental (normal pattern) innovation is facilitated by networks that self-organize to access and synthesize the diverse body of tacit and codified knowledge needed to rapidly carry out these innovations. This is particularly important because incremental innovations are the most financially beneficial to the innovators. For simple technologies, centralized decision-making is possible even during the normal pattern. Successful centralized decision-making requires decision-makers to have understanding derived from extensive codification of the needed knowledge and/or the range of tacit knowledge needed to make informed decisions. The movement of a technology from simple to complex typically requires major efforts to codify existing tacit knowledge. As the complexity of the technology increases and the rate of its innovation increases, this codification response becomes less and less adequate. It is at this point, then, that only networks will suffice. Conclusions Bosch diesel fuel injection systems provide an illustration of the technological and organizational co-evolution associated with the innovation of complex technologies. The case offers insight into the evolution from a simple mechanical system to increasingly complex 25 electro-mechanical systems. At the same time, the organization responsible for carrying out the innovation has evolved from a small specialized Bosch group to an international alliance-based network comprised of suppliers, end-users, universities and several Bosch organizations. One consistent characteristic of the Bosch organization suggested by a review of the injection technology history is that Bosch is very good at incremental innovations and systems know-how. Repeatedly the organization has demonstrated special skill in fitting new product designs to the market. This is done primarily by carrying out incremental innovations and putting major emphasis on production and servicing innovations that either structure or quickly respond to the market. In the contemporary period this means being able to rapidly deliver specialized systems that meet the needs of customers. Contemporary innovation success requires being able to produce a unique injection system for the new engine modifications that user companies are carrying out on a repeated basis. The absence of the “not invented here” syndrome is particularly striking. The selforganizing network clearly learns from any source and exchanges knowledge with its network partners. In addition Bosch has used the innovation of a very wide range of specific fuel injection systems, for example the unit injector, to create competition within its own diesel fuel injection network. Each of the major designs is to some extent in competition with the others. The result of this is that the different injection systems compete with each other for market share. There are thus powerful incentives to make incremental innovations. There are also powerful incentives for driving the learning of the network as a whole. The existence of the multiple injector system networks centered in the DS division creates a situation where learning in one injection system network gets rapidly transferred to other injection system networks. This is clearly evident in the development of improved process technologies. Where it has high volume production, Bosch seeks to have two manufacturing plants to assure a continued supply in case of difficulty at one plant. One of the benefits of this approach is that the plants contribute to each other’s learning. Bosch is a high trust organization. The Bosch culture appears to limit the incentives for opportunistic behavior both on the part of individuals and organizational units. Several observations about the high trust character of the Bosch network are warranted. First, there is substantial emphasis on the specialized skills of people and organizations in the Bosch network. It appears generally correct to characterize the Bosch network as one composed or organizations 26 and people who perceive their identities in terms specialized in-depth knowledge and skills as opposed to generalists. Second, there appears to be substantial competition among the people and organizations that make up the network and with other networks in Bosch in their pursuit of technology innovations. Third, Bosch appears to have a culture that allows it to gain the benefits of the incentives that come from competition within the network and company and also the benefits that come from cooperation and pursuit of a shared set of goals. The Bosch-centered network has developed a capacity whereby engine designers and manufacturers who are competitors are willing to share their knowledge with Bosch because they have confidence that their proprietary knowledge will not be communicated to other competitors. This has two benefits. First, it allows for rapid joint innovation between Bosch and the engine producers. Second, it allows for Bosch to enjoy the range of learning that comes from innovative interactions with a range of engine producers. The generic learning that the Bosch network acquires from carrying out innovations with many engine producers flows back to all engine producers. The pattern of cooperation and competition could not work without trust. Specifically, the ability to carry out transition pattern innovations, those that have involved new designs and require the integration of new core capability knowledge, has been facilitated by the atmosphere of trust. It is commonly a major management challenge for companies to carry out the innovation of technologies that require merging previously separate but equal bodies of technical knowledge, e.g., the first innovation of electro-mechanical technologies. Merging diverse technical communities involves the merging of separate technical/organizational cultures. The Bosch trust environment appears to have made the major change in the organizational network necessary to carry out the innovation of electro-mechanical technologies work more smoothly than often occurs. 27
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