SIMULATION-BASED PERFORMANCE ANALYSIS FOR FUTURE ROBUST MODULAR PRODUCT ARCHITECTURES

The increased demand for customer-adapted product solutions shows an increasing trend of product variety, leading to an increased internal variety and therefore -costs. The concept of modularization provides apossible solution to this challenge by developing modular kits. Nevertheless, modularization methods to not lead to one individual modular kit, but to several alternatives. The decision of which alternative to implement can be crucial to the applying companys succes. During this decision-making both customer- and company perspectives need to be taken into account. This contribution is to present a simulation-based approach to support the decision making by using a model-based configuration system. Furthermore, as classical decision-making processes are based upon historical data, future aspects are usually not taken into account. In order to counteract this situation, this contribution intends to simulate as well future aspects impacting the modular product architecture. In this case, the simulation is used in order to evaluate the individual performances of a Design-for-Variety product architecture as opposed to a Design-for-Future-Robustness by applying this method to the example of customer-individual laser machines.

Design-for-variety and operational performance

Purpose Design-for-variety (DFV) practices aim to help manufacturers to manage and mitigate the negative impact of product variety on operational performance. Theory suggests that designing products according to DFV practices increases operational performance by allowing more efficient processing of products, capitalizing on commonalities and by supporting cross-functional and cross-boundary coordination through simplifying product designs. The purpose of this paper is to investigate the latter proposition, and especially the mediating role of internal, supplier and customer integration in the relationship between DFV and operational performance. Design/methodology/approach Data collected in 2014 among 702 manufacturers from 22 countries as part of the 6th International Manufacturing Strategy Survey are analyzed through mediated regression analysis using SPSS 25, AMOS and PROCESS v3.1 software. Findings DFV affects cost/speed, quality, delivery, flexibility and service performance positively. Except for the role of customer integration in the DFV-cost/speed relationship, internal, supplier and customer integration partially mediate the relationship between DFV and operational performance. Practical implications In addition to allowing a more efficient processing of products, the positive effect of DFV on performance is also explained by the fact that DFV practices support cross-functional and supply chain integration. These practices allow manufacturers to create a set of design rules easily understood and communicated within and across organizational boundaries. Originality/value While previous research tends to consider one DFV practice and limited sets of integration mechanisms and performance dimensions, this paper consolidates the most common DFV practices into one construct and encompasses the three forms of integration and six performance dimensions dominating the DFV literature.

Computer-Aided Generation of Modular Designs Considering Component End-of-Life Options: Implications for the Supply Chain

Given the growing demand for product customization, modularization is a viable way to reduce the complexity of new product development. This study presents a framework to incorporate component end-of-life options through modularization during the early design stages, to simultaneously account for supply chain factors as well as evaluating design variants. In order to accomplish this, we extend an existing software framework; this software is aimed at creating a computational design tool to aid designers in developing new modular products, by taking into account design for assembly (DfA) and design for variety (DfV). We present an extension to that work where the user has the ability to generate modular designs considering component end-of-life options, and to optimize relevant supplier selections, either to minimize costs or carbon footprint. We compare the results of this modularization with the widely used decomposition approach (DA). Overall, this computational tool enables users to understand the trade-offs between product design and supply chain performance, and the presented investigation on the two modularization methods (DA and Green DA) attests to the implications of design decisions throughout the supply chain and across the product life cycle.

An Integrated Model of Designing

Current design models and frameworks describe various overlapping fragments of designing. However, little effort exists in consolidating these fragments into an integrated model. We propose a model of designing that integrates product and process facets of designing by combining activities, outcomes, requirements, and solutions. Validation of the model using video protocols of design sessions demonstrates that all the constructs are used naturally by designers but often not to the expected level, which hinders the variety and resulting novelty of the concepts developed in these sessions. To resolve this, a prescriptive framework for supporting design for variety and novelty is proposed and plans for its implementation are created.

Framework for Generating Modularized Product Designs With Assembly and Variety Considerations

Conceptual design is found to be the most ambiguous and creative phase of design. There exist only a few computational tools that aid designers at conceptual design stage, and mostly designers rely on personal experience or experience of coworkers to generate quality designs. The proposed framework aims at generating robust computerized conceptual designs by incorporating Modularity, Design for Assembly (DFA) and Design for Variety (DFV) principles at the conceptual stage. Conceptual design alternatives obtained from the proposed framework are ranked based on minimum assembly time, and are composed of modules in a way that future changes in customer needs are satisfied only by replacing certain modules. The framework involves searching a design repository of components by using functional-basis and pre-defined graph grammar rules, to generate all possible conceptual design alternatives. These design alternatives are ranked and filtered using a DFA index, and top two alternatives are selected. Selected designs are modularized and filtered using a DFV index to obtain the best design alternative. This paper provides a detailed discussion of the framework obtained by amalgamating Modularity, DFA, and DFV. Working of the proposed framework is demonstrated with the help of an electronic toothbrush design example.

Assembly and Variety Considerations During Conceptual Design

Foremost step in the development of any electromechanical product is its design, and conceptual design is the most ambiguous and creative phase of design. There exist only a few computational tools that aid designers at conceptual design stage, and mostly designers rely on personal experience or experience of co-workers to generate quality designs. The proposed framework aims at generating robust computerized conceptual designs by incorporating Modularity, Design for Assembly (DFA) and Design for Variety (DFV) principles at the conceptual stage. Conceptual design alternatives obtained from the proposed framework are ranked based on minimum assembly time, and are composed of modules in a way that future changes in customer needs are satisfied only by replacing certain modules. The framework involves searching a design repository of components by using functional-basis and pre-defined graph grammar rules, to generate all possible conceptual design alternatives. These design alternatives are ranked and filtered using a DFA index, and top two alternatives are selected. Selected designs are modularized and filtered using a DFV index to obtain the best design alternative. This paper provides a detailed discussion of the proposed framework, and its working is illustrated through the design of a mounting system for holding a Variable Message Sign (VMS).