Planning and scheduling in the automotive industry: A comparison of industrial practice at German and Japanese makers

Providing customization of products is an important way of attracting customers, but it can increase the complexity of planning and scheduling processes in the order fulfilment system. Thus the question arises, how product variety, manufacturing conditions and managerial practices interact with the planning and scheduling functions of a firm. In order to improve this understanding, we compare the order fulfilment system of German and Japanese auto makers as a sample of industrial practice. From 2007 to 2012 we engaged in a total of 56 interviews related to planning and plant scheduling functions in both sales and operations activities to analyse similarities and differences between German and Japanese auto makers. As part of this research we conducted two in-depth case studies at one German and one Japanese auto maker to map planning and scheduling functions along the order fulfilment process. Additionally, we relate those findings with secondary data sources. Our sample reveals a great variation in manufacturing conditions, product variety, and managerial practices in order fulfilment at Japanese and German auto makers. However, contrary to common perception, planning and scheduling processes differ much less between auto makers even in the light of regional differences concerning order fulfilment, different levels of product variety and mixed-model line manufacturing practice. We conclude with a discussion on variations and similarities between auto makers and the possibility of merging different practices with theoretical advances. •We compare the order fulfilment system and managerial practices of German and Japanese makers.•Our sample reveals a great variation in product variety and manufacturing conditions.•However, contrary to common perception, planning and scheduling processes differ much less.•We conclude with propositions on the possibility of merging practices with theoretical advances.