Digital Supply Chain Twin:
Framework for Planning and Control of Logistics Systems
vorgelegt von
M. Sc.
Simon Zarnitz
ORCID: 0009-0003-6251-3581
an der Fakultät VII – Wirtschaft und Management
der Technischen Universität Berlin
zur Erlangung des akademischen Grades
Doktor der Wirtschaftswissenschaften
-Dr. rer. oec.-
genehmigte Dissertation
Promotionsausschuss:
Vorsitzender: Prof. Dr. Rüdiger Zarnekow
Gutachter: Prof. Dr.-Ing. Frank Straube
Gutachter: Prof. Dr.-Ing. Florian Schupp
Tag der wissenschaftlichen Aussprache: 04. Juli 2023
Berlin 2023
II Content
CONTENT
LIST OF FIGURES ............................................................................................................................................ IV
LIST OF TABLES ......................................................................................................................................... VI
LIST OF ABBREVIATIONS ....................................................................................................................... VII
1 INTRODUCTION .................................................................................................................................. 1
1.1 MOTIVATION AND PROBLEM STATEMENT ..................................................................................................... 1
1.2 RESEARCH OVERVIEW AND OBJECTIVES ........................................................................................................ 5
1.3 EXPECTED OUTCOMES AND LIMITATIONS ...................................................................................................... 8
1.4 THESIS OUTLINE .................................................................................................................................... 10
2 THEORETICAL BACKGROUND ............................................................................................................ 13
2.1 SELECTED THEORIES ................................................................................................................................ 13
2.1.1 SYSTEMS THEORY ________________________________________________________________ 14
2.1.2 MANAGEMENT THEORY ___________________________________________________________ 18
2.1.3 NETWORK THEORY _______________________________________________________________ 20
2.2 FUNDAMENTALS OF LOGISTICS .................................................................................................................. 24
2.2.1 LOGISTICS SYSTEMS ______________________________________________________________ 25
2.2.2 OBJECTIVES OF LOGISTICS __________________________________________________________ 27
2.2.3 PLANNING AND CONTROL OF LOGISTICS SYSTEMS __________________________________________ 28
2.2.4 NETWORK MANAGEMENT __________________________________________________________ 29
2.3 INTRODUCTION TO DIGITAL SUPPLY CHAIN TWINS ........................................................................................ 30
2.3.1 FUNDAMENTALS OF DIGITAL SUPPLY CHAIN TWINS _________________________________________ 30
2.3.2 TECHNOLOGICAL ENABLERS OF DIGITAL SUPPLY CHAIN TWINS _________________________________ 35
2.4 CURRENT MANAGERIAL FRAMEWORKS: DSCT ............................................................................................. 36
3 METHODOLOGY ................................................................................................................................ 40
3.1 OVERVIEW OF THE DATABASE .................................................................................................................. 41
3.2 SYSTEMATIC LITERATURE REVIEW .............................................................................................................. 43
3.3 EXPERT SURVEY .................................................................................................................................... 50
3.4 WORKSHOP ......................................................................................................................................... 51
3.4.1 NOMINAL GROUP TECHNIQUE _______________________________________________________ 55
3.4.2 Q METHODOLOGY _______________________________________________________________ 57
3.5 CASE STUDY EXPLORATION ...................................................................................................................... 58
3.5.1 CASE STUDY I: AFTERMARKET DATA – TECHNICAL REQUIREMENTS ______________________________ 59
3.5.2 CASE STUDY II: PROTOTYPICAL IMPLEMENTATION __________________________________________ 61
3.6 EXPERT INTERVIEWS ............................................................................................................................... 62
3.6.1 SEMI-STRUCTURED INTERVIEWS ______________________________________________________ 62
3.6.2 STRUCTURED INTERVIEWS __________________________________________________________ 64
4 CONCEPTUAL CLARIFICATION: DIGITAL SUPPLY CHAIN TWINS ......................................................... 65
III Content
4.1 SCOPE OF DIGITAL TWINS AND DIGITAL SUPPLY CHAIN TWINS ......................................................................... 65
4.2 AREAS OF APPLICATION OF DIGITAL SUPPLY CHAIN TWINS .............................................................................. 66
4.3 LOGISTICAL USE CASES AND THEIR POTENTIAL ............................................................................................... 69
4.3.1 NETWORK MANAGEMENT __________________________________________________________ 69
4.3.2 TRANSPORTATION _______________________________________________________________ 71
4.3.3 MANUFACTURING _______________________________________________________________ 72
4.3.4 CARGO HANDLING _______________________________________________________________ 73
4.3.5 WAREHOUSING _________________________________________________________________ 75
5 DESIGN AND IMPLEMENTATION FRAMEWORK ................................................................................ 76
5.1 DEVELOPMENT OF THE DESIGN AND IMPLEMENTATION FRAMEWORK FOR DSCT-ENABLED PLANNING AND CONTROL .... 77
5.2 PHASE 0: NEED FOR A DSCT .................................................................................................................... 84
5.3 PHASE 1: ORGANISATIONAL AND PROCESSUAL REQUIREMENTS FOR DSCT APPLICATIONS ...................................... 86
5.3.1 ORGANISATIONAL REQUIREMENTS ____________________________________________________ 88
5.3.2 PROCESSUAL REQUIREMENTS ________________________________________________________ 90
5.4 PHASE 2: IDENTIFICATION OF TECHNOLOGICAL AND DATA-RELATED REQUIREMENTS FOR DSCT APPLICATIONS ............ 93
5.5 PHASE 3: DESIGN AND IMPLEMENTATION GUIDELINE ..................................................................................... 96
5.5.1 BARRIERS TO SUCCESSFUL IMPLEMENTATION _____________________________________________ 99
5.5.2 OPPORTUNITIES FOR DSCT ________________________________________________________ 101
5.6 PHASE 4: POST-IMPLEMENTATION .......................................................................................................... 106
5.6.1 IMPLEMENTATION COSTS _________________________________________________________ 108
5.6.2 MAINTENANCE AND SERVICE COSTS __________________________________________________ 110
5.6.3 EVALUATION: RELATIONSHIP BETWEEN COST DRIVING FACTORS AND COST BLOCKS ___________________ 113
5.7 VALIDATION OF THE DESIGN AND IMPLEMENTATION FRAMEWORK .................................................................. 115
6. FROM THEORY TO PRACTICE: A FEASIBILITY ASSESSMENT OF THE FRAMEWORK ........................... 120
6.1 CASE STUDY I: REQUIREMENTS FOR SUCCESSFUL IMPLEMENTATION ................................................................ 121
6.2 CASE STUDY II: PRACTICAL IMPLEMENTATION OF A PROTOTYPE ..................................................................... 125
6.2.1 VALIDATION OF DSCT POTENTIALS ON THE BASIS OF REPRESENTATIVE LOGISTICS USE CASES _____________ 130
6.2.2 POST-IMPLEMENTATION __________________________________________________________ 140
7. DISCUSSION OF THE FUTURE IMPACT OF THE DSCT ON LOGISTICS ................................................. 141
7.1 FUTURE PATHWAYS OF COOPERATION IN LOGISTICS SYSTEMS ......................................................................... 141
7.2 HUMAN FACTORS: IMPLEMENTATION OF DSCT FOR LOGISTICS ...................................................................... 144
7.3 IMPLICATIONS FOR PLANNING AND CONTROL ............................................................................................ 148
7.4 REQUIREMENTS FOR A DSCT: A BOTTOM-UP-APPROACH ............................................................................ 150
8 CONCLUSION AND OUTLOOK .......................................................................................................... 154
8.1 SUMMARY ......................................................................................................................................... 154
8.2 SCIENTIFIC AND MANAGERIAL CONTRIBUTION ............................................................................................ 156
8.2.1 MANAGERIAL CONTRIBUTION ______________________________________________________ 157
8.2.2 SCIENTIFIC CONTRIBUTION ________________________________________________________ 159
8.3 OUTLOOK AND FURTHER RESEARCH .......................................................................................................... 162
8.4 CRITICAL ACKNOWLEDGEMENT ............................................................................................................... 163
REFERENCES ................................................................................................................................................. 165
IV List of Figures
LIST OF FIGURES
Figure 1 Research design __________________________________________________________ 7
Figure 2 Thesis outline ____________________________________________________________ 11
Figure 3 Concepts of System Theory _________________________________________________ 16
Figure 4 Critical Success Factors Logistics _____________________________________________ 27
Figure 5: DSCT Understanding _____________________________________________________ 33
Figure 6 Disruption Risks __________________________________________________________ 37
Figure 7 Technical Overview of a DSCT _______________________________________________ 38
Figure 8 Data For a Digital Twin _____________________________________________________ 39
Figure 9 Methodology and Explanation ________________________________________________ 41
Figure 10 Database: Dissertation ____________________________________________________ 42
Figure 11 SLR Papers and Forward Citation ___________________________________________ 46
Figure 12 Distribution of Key Papers _________________________________________________ 47
Figure 13 Application of Inclusion Criteria ______________________________________________ 48
Figure 14 SLR Clustering __________________________________________________________ 49
Figure 15 Workshop: Company Size _________________________________________________ 53
Figure 16 Nominal Group Technique _________________________________________________ 55
Figure 17 Schedule of Semi-Structured interviews _______________________________________ 63
Figure 18 List of Structured Interviews ________________________________________________ 64
Figure 19 Scope of digital supply chain twins ___________________________________________ 65
Figure 20 Application Areas DSCT ___________________________________________________ 67
Figure 21 Design and implementation Framework _______________________________________ 76
Figure 22 Structure of the Design and Implementation Framework __________________________ 78
Figure 23 Research Questions and Design and Iimplementation Framework __________________ 81
Figure 24 Databases, Methods and the Design and Implementation framework _______________ 82
Figure 25 Outcome: Phase 0________________________________________________________ 84
Figure 26 Outcome of Phase I ______________________________________________________ 87
Figure 27 Organisational Requirements _______________________________________________ 88
Figure 28 Processual Requirements __________________________________________________ 91
Figure 29 Outcome: Phase II________________________________________________________ 93
Figure 30 Data Sources DSCT ______________________________________________________ 94
Figure 31 Outcome: Phase III _______________________________________________________ 96
Figure 32 Generalization Approach: Benefits of DSCT ___________________________________ 101
Figure 33 Benefits of DSCT________________________________________________________ 102
Figure 34 Use-Case Benefits ______________________________________________________ 104
V List of Figures
Figure 35 Outcome of Phase IV ____________________________________________________ 106
Figure 36 Cost Blocks: Implementation Costs _________________________________________ 108
Figure 37 Cost Blocks: Maintenance _________________________________________________ 110
Figure 38 Service and Maintenance Costs: Interview Results _____________________________ 111
Figure 39 Median Service Costs ____________________________________________________ 111
Figure 40 Quartiles of Service Costs _________________________________________________ 112
Figure 41 Data Sources for a DSCT _________________________________________________ 122
Figure 42 Supplier Network: DSCT Prototype__________________________________________ 126
Figure 43 Production Network: DSCT Prototype _______________________________________ 127
Figure 44 Scenario IV: Supplier Default ______________________________________________ 132
Figure 45 Scenario II: Spare Parts __________________________________________________ 135
Figure 46 Scenario III: Finished Components __________________________________________ 137
Figure 47 Scenario IV: Customer Satisfaction _________________________________________ 139
Figure 48 DSCT: Three-Stage Diagram ______________________________________________ 148
Figure 49 Bottom-Up Approach to the DSCT __________________________________________ 151
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