Application of the Copy Exact methodology to systems implementation

Abstract

Manufacturing companies that successfully grow their markets and operations face the challenge coordinating operations to capture the value created by economies of scale. However, sharing best practices across organizations requires diligent coordination between the multiple business units. This research describes and examines a method for coordination and knowledge transfer commonly referred to as Copy Exact. This method, often associated with technology transfer in semiconductor fabrication facilities, can be readily applied to implementation of large-scale information systems. By sharing the collective knowledge and resources of multiple independent groups within a larger organization, the Copy Exact approach can lower total development and implementation costs, accelerate the time required for full solution deployment, and improve likelihood of smooth, trouble-free implementations. However, the close coordination required to execute the Copy Exact approach gives rise to significant coordination costs, and requires careful attention to methods of communication and knowledge sharing applied. Dell Computer Corporation has applied the Copy Exact methodology to implement factory level supply chain integration package across its 12 worldwide manufacturing facilities. The decision to apply Copy Exact during implementation of the DSi2 system at Dell yielded significant benefits for the cost, speed, stability, and sustainability of the project. However, Copy Exact also created challenges of factory specific software customization and of trans-global project support. The nature and significance of these benefits and challenges are detailed and, where possible, quantified in this thesis. Further, tactics useful for maximizing the Copy Exact benefits and managing the challenges are presented. The findings of this research indicate that Copy Exact can be successfully applied to information systems implementations. Dell stands to benefit from further application of Copy Exact to multi-factory projects, and similar manufacturing organizations can learn from Dell's example.