Mapping Product Design Specification for Mass Customization

Mass customization is an emerging field in manufacturing research community where customer satisfaction is achieved by complying with exact customer requirements at mass production efficiencies. Product varieties have mostly failed in the aspect of satisfying customer requirements, since knowing beforehand exactly what customer needs is beyond the scope of any manufacturing or marketing paradigm. So design to order and build to order is widely talked in the industry to capture heterogeneous market segments. In order to achieve the challenging task of customization at mass production efficiencies, a tight integration of the various entities involved is necessary. Gathering customer requirements, finalizing product design and eventual manufacturing need to be seamlessly integrated to achieve mass production efficiencies. Product designs are classified into customizable product platform families, and then searched based on customer requirements to identify the most conformal design family. Finally the design parameter transport is carried out from customer domain to product domain. Eventually a valid and realizable product specification is generated. The paper will address these issues of classification, selection and ultimately the mapping of parameters. A methodology to classify the product design information, which can easily accommodate design variations based on product platform architecture is proposed. Further, adaptive design customization, which relates most design parameters with the scalable platform design parameters using matrix formulation, is discussed. The proposed design parameter classification and adaptive synthesis of design parameters is applied to a spring design example.     

Progressive sharing of modules among product variants

Recent market transition from mass production to mass customization forces manufacturers to design products that meet individual requirements. In order to address the high cost of this practice, manufacturers develop product families with a common platform, whose variants are designed to meet different customer demands. Parallel to this transition, the dynamics of the market forces designers to develop products composed of modules that are standardized as much as possible across products, thus can be more resilient than complete designs in a changing world.Starting from an original set of different components, our method designs a modular common platform and additional modules, shared by subsets of the designs, from which variants are composed.We applied the method to the layout design of a set of products. Consequently, the geometric aspect of the product family optimization is emphasized, but functional aspects related to the product features and to customer needs are also addressed due to their manifestation in the layout. The design search space is explored using shape grammar rules that alter component geometry and therefore, functionality. The search for optimal design is performed using simulated annealing. Given different objective formulations or parameter settings, the method can be used to explore the solution space. A simple example problem demonstrates the feasibility of the method.     

The art of requirements triage

Driven by an increasingly competitive market, companies add features and compress schedules for the delivery of every product, often creating a complete mismatch of requirements and resources that results in products failing to satisfy customer needs. Triage is the process of determining which requirements a product should satisfy given the time and resources available. The author presents three product development case studies and 14 recommendations for practicing this neglected art.     

A system framework for OKP product planning in a cloud-based design environment

Nowadays, one-of-a-kind (OKP) companies, which generally operate in an 'engineer-to-order' business mode, strive to deliver individualized products with quality to achieve customer satisfaction. Thus, an accurate and prompt analysis of customer requirements (CRs) in the early design stage is critical to its success. However, most OKP companies are small or medium-sized enterprises (SMEs). Due to the limited resources and low product planning budget, they often cannot obtain abundant CR information nor can they afford the expense of complicated planning process. To address these issues, a system framework is proposed in support of OKP product planning process in a cloud-based design (CBD) environment. The challenges and future market niches of OKP companies are presented. The comparison of typical distributed systems shows that CBD, which utilizes advanced information technologies and business model, has advantages in providing sufficient resources, decreasing product development time span for OKP companies in a cost-efficient way. This article describes the proposed system architecture, the business interaction process and the information communication among customers, designers and marketing analysts at the product planning stage. To validate the proposed framework, a prototype system module MyProduct is under development in the CBD environment with an illustrative example.     

Multiple platforms design and product family process planning for combined additive and subtractive manufacturing

Industry 4.0 promotes the utilization of new exponential technologies such as additive manufacturing in responding to different manufacturing challenges. Among these, the integration of additive and subtractive manufacturing technologies can play an important role and be a game changer in manufacturing products. In addition, using product platforms improves the efficiency and responsiveness of manufacturing systems and is considered an enabler of mass customization. In this paper, a model to design multiple platforms that can be customized using additive and subtractive manufacturing to manufacture a product family cost-effectively is proposed. The developed model is used to determine the optimal number of product platforms, each platform design (i.e. its features set), the assignment of each platform to various product variants, and the macro process plans for customizing the platforms while minimizing the overall product family manufacturing cost.The multiple additive/subtractive platforms and their process plans are determined by considering not only the commonality between the product variants but also their various manufacturing cost elements and the customer demand of each variant. The design of multiple product family platforms and their process plans is NP-hard problem. A genetic algorithm-based model is developed to reduce the computational complexity and find optimal or near optimal solution. Two case studies are used to illustrate the developed multiple platform model. The model results were compared with a single platform model in literature and the results demonstrate the multiple platform model superiority in manufacturing product families in lower cost. The use of the developed model enables manufacturing product families cost efficiently and allows manufacturers to manage diversity in products and market demands.     

浅谈家具大批量定制

随着生活质量的提高,人们对居室装饰的要求越来越高,对居室家具需求逐渐向少量多样化发展,通过定制化家具来表现家庭居室的装饰风格来满足个人需求。因此,企业应以顾客需求为导向,通过实施家具定制化策略,以定制化的家具生产与服务来提高家具附加价值与企业竞争能力,从而适应市场的发展。     

面向柔性客户需求的产品变型设计方法

针对柔性的客户定制需求,提出充分重用零件实例的产品变型设计方法.通过分析零件实例重用引起的尺寸约束冲突,提出基于尺寸变化概率和零件变型需求的尺寸约束冲突转移与延迟解决方案,并给出了尺寸变化概率和零件变型需求的统计模型;然后针对零件实例重用引起的客户需求损失提出定制特征指标的补偿作用,并以田口质量损失函数为基础构建了改进的客户需求损失综合模型.最后通过一个实例进行了验证,结果表明在产品变型设计过程中,选择对客户需求影响小的零件实例作为重用对象,可以实现在满足客户需求的同时有效地降低定制产品的成本、缩短交货期.     

Towards product customization: An integrated order fulfillment system

To stay competitive, manufacturing companies nowadays pursue product customization; and configure-to-order (CTO) has been recognized as an ideal business model to implement product customization. Due to the complexities resulting from the large number of customized products, an increased attention has been paid to the order fulfillment process in CTO. However, most of the solutions delivered either focus on own interested areas without considering the impacts from/on the others or approach order fulfillment processes from a strategic level. In view of the limitations of existing solutions and the significance of order fulfillment activity automation and integration, this study considers the entire spectrum of order fulfillment process at an operational level and, proposes an integrated order fulfillment system (IOFS). The IOFS is designed to (1) automatically execute order processing, which is conventionally undertaken in a face-to-face manner; (2) configure products and process plans based on product and process family models; and (3) allow real-time data extraction and sharing of the latest information. Therefore, it assists companies to quickly respond to diverse customer requirements and deliver the expected products at low costs. An industrial example of turn unit assemblies is presented to demonstrate the feasibility and potential of the IOFS for product customization.     

An agent-based recommender system for developing customized families of products

Electronic markets and web-based content have improved traditional product development processes by increasing the participation of customers and applying various recommender systems to satisfy individual customer needs. Agent-based systems based on agents’ roles and tasks can provide appropriate tools to solve product design problems by recommending design knowledge and information. This paper introduces an agent-based recommender system to support designing families of products based on customers’ preferences in dynamic electronic market environments. In the proposed system, a market-based learning mechanism is applied to determine the customers’ preferences for recommending appropriate products to customers of the product family. We demonstrate the implementation of the proposed recommender system using a multi-agent framework. Through simulated experiments, we illustrate that the proposed recommender system can help determine the preference values of products for customized recommendation and market segment design in various electronic market environments.     

Integrated Vehicle Configuration System—Connecting the domains of mass customization

Configuration design for mass customized vehicles necessitates the coordination of customer requirements, product characteristics, production processes, and logistics networks, in order to achieve rapid response to customer orders. Existing product configurators are mainly used as sales tools, and fail to account for the requirements of the entire customer order fulfillment process. In this regard, this paper proposes an Integrated Vehicle Configuration System (IVCS) to facilitate customer order processing based on information from multiple domains in a mass customization environment. An IVCS business model is proposed to incorporate the decision factors for configuration design related to different planning stages. The business model is supported by a comprehensive ontology framework, which enhances communications between different stakeholders involved in the order fulfillment process. The configuration approach is based on combinations of selective and generative rules and can be integrated with existing ERP systems. It also provides mechanisms to handle configuration rules that allow users to convert soft preferences into product specifications, bill-of-materials, and, furthermore, into logistics configurations. An example of a computerized configuration system showcases the process from customer engineering to design and production.     

Integrated product and manufacturing system platforms supporting the design of personalized medicines

Pharmaceutical product customization, a prerequisite for personalized medicines, is currently a widely researched topic. Patient characteristics can be mapped and translated into parameters for designing patients’ individual treatment, i.e., the dosage form. However, current pharmaceutical manufacturing is dominated by mass production and lacks the capability and flexibility required to produce customized products. Mass customization is a proven successful approach in, for example, the manufacturing industry and thus has been discussed as an enabler for pharmaceutical product customization but has never been fully explored in a pharmaceutical context. Inspired by mass customization approaches in the manufacturing industry, this study proposes a novel methodology to develop integrated product and manufacturing system platforms for pharmaceutical products supporting a mass customization paradigm. The proposed methodology establishes sets of product and manufacturing system platform variants and suggests an approach to feasible platform design selection. The applicability of the proposed methodology is illustrated for diabetes treatment as a selected case example. Integrated platform designs are developed for the conventional treatment of a fully integral tablet design and for a design enabling product customization with a modularized tablet design. The manufacturing platforms are still embracing a mass production design in the methodology illustration and should elicit knowledge on the utility of the current production design in a mass customization context. The performance and utility of the respective platform are assessed in terms of production cost and patient benefit. The results suggest a substantial increase in patient benefit afforded by the modularized tablet design, however the production cost is increased. This trade-off between the production cost and patient benefit thus calls for novel manufacturing system concepts to achieve the feasible manufacturing of customized pharmaceutical products.     

A KE-LSA approach for user-centered design

In today’s highly competitive business environment, most successful companies use ‘user-centered’ design techniques, to create products that meet user needs. Designers have used traditional user-centered design techniques, with some degree of success. However, in today’s market, companies need more accurate, more advanced user-centered design techniques, to mass produce customized products for individual users. This study introduces a new KE-LSA approach for user-centered design. Prior techniques used Kansei engineering (KE) for product design. Prior techniques used latent semantic analysis (LSA) for document indexing. The KE-LSA approach uses KE and a KE-LSA semantic space for individually customized product design. A case study is used to describe the KE-LSA approach. The case study uses the KE-LSA approach to match Kansei values for individual users’ needs to cell phone designs for each user. The case study also determines accuracy for matching KE-LSA designs to each user’s actual choice for a cell phone. In the case study, an iterative KE-LSA approach matched designs to users’ choices, with 82.3% overall accuracy. The iterative KE-LSA approach improved overall accuracy 11.4%, compared to a traditional iterative KE-QT1 approach. The KE-LSA approach improves matching accuracy for mass producing individually customized cell phone designs. Therefore, this study improves individually customized product design and product quality.     

A manufacturing-oriented approach for multi-platforming product family design with modified genetic algorithm

With highly fragmented market and increased competition, platform-based product family design has been recognized as an effective method to construct a product line that satisfies diverse customer’s demands while aiming to keep design and production cost-effective. The success of the resulting product family often relies on properly resolving the inherent tradeoff between commonality across the family and performance loss. In this paper, a systematic multi-platforming product family approach is proposed to design a scale-based product family. In the light of the basic premise that increased commonality implies enhanced manufacturing efficiency, we present an effective platform decision strategy to quantify family design configuration using a commonality index that couples design varieties with production variation. Meanwhile, unlike many existing methods that assume a single given platform configuration, the proposed method addresses the multi-platforming configuration across the family, and can generate alternative product family solutions with different levels of commonality. A modified genetic algorithm is developed to solve the aggregated multiobjective optimization problem and an industrial example of a planetary gear train for drills is given to demonstrate the proposed method.     

Mass customization in the product life cycle

This study presents an introduction to mass customization in the product life cycle—the goal of mass customization, mass customization configurations, and new customer integration techniques, modular design techniques, flexible manufacturing systems (FMSs), and supply chain management methods. The study reviews three selected books and twenty-one selected papers—early papers that describe the goal of mass customization, early papers that describe mass customization configurations, and recent papers that describe new customer integration techniques, modular design techniques, FMSs, and supply chain management methods. The study shows that the goal of mass customization is to create individually customized products, with mass production volume, cost, and efficiency, that most companies use ‘assemble-to-order’ configurations to create standardized products, and that more work is needed on interactive customer integration techniques, collaborative modular design techniques, reconfigurable manufacturing systems, and integrated supply chain management methods to achieve the goal of mass customization.     

Supporting management and maintenance of manufacturing knowledge in design automation systems

Many companies base their business strategy on customized products. To enable a high level of product adaptation in an engineer-to-order approach companies invest time and resources to develop design automation systems. Initially, when implementing a design automation system, the focus is on successfully developing a system that generates design variants based on different customer specifications (i.e. the execution of system embedded knowledge and system output). However, in the long run, two important aspects are the management and maintenance of the knowledge that governs the designs. Further, the increasing emphasis on deploying a holistic view of a product’s properties and functions implies an increasing number of life-cycle requirements. The knowledge to adapt the product to fulfil these requirements should also be used and consequently incorporated into the knowledge-base, allowing for correct decisions to be made. In a system for automated variant design, the implications on the product of these life-cycle requirements have to be expressed as algorithms, production rules and/or computational statements to be intertwined with the design calculations. The number of requirements can be significantly large, and the knowledge scattered over different application systems used for the realisation of the design automation system. This makes it difficult to manage and maintain the system as the product life-cycle environment changes and evolves.In this article, the focus is on the requirements related to manufacturing. For that, an approach for the modelling of manufacturing requirements, supporting both knowledge execution and information management, in systems for automated variant design is introduced. The approach has been applied and refined when developing a design automation system in cooperation with a company to demonstrate and verify the approach’s usability.     

Customer satisfaction evaluation method for customized product development using Entropy weight and Analytic Hierarchy Process

Providing customized products with high customer satisfaction (CS) has become an inevitable trend for modern customized companies to remain competitive. This study proposes a CS evaluation method for customized product development using Entropy weight and Analytic Hierarchy Process (AHP). Firstly, customer requirements are identified based on Voice-of-Customer (VoC), and classified into four categories (positive, negative, must-be and fuzzy attributes) according to the characteristics of CS criteria. Then, CS evaluation model and its solution method are introduced in detail. This study especially focuses on the quantitative methods for each category of the evaluation criteria through formulating several mathematical models, and criteria weights are obtained through integrating Entropy weight and AHP method. Finally, a case study of applying the proposed methodology to customized portrait-based product industry demonstrates the functionality of the proposed methodology.     

Combining fuzzy AHP and fuzzy Kano to optimize product varieties for smart cameras: A zero-one integer programming perspective

In an era of global customization, dominating the majority market with a single product has become increasingly difficult and almost impossible for most companies. In contrast, they must provide various product varieties that attract diverse customers, particularly when acquiring distinct market segments. In practice, however, most companies cannot effectively reduce the gap between customer requirements and design characteristics, although this impacts the profitability and future growth of companies. Meanwhile, companies often get stuck in the trade-offs between enhancing product varieties and controlling manufacturing costs. Accordingly, this paper proposes a hybrid framework that combines fuzzy analytical hierarchy process (AHP), fuzzy Kano model with zero-one integer programming (ZOIP) to incorporate customer preferences and customer perceptions into the decision-making process of product configuration. Specifically, fuzzy AHP is used to extract customer preferences for core attributes while fuzzy Kano model is utilized to elicit customer perceptions of optional attributes. Finally, by virtue of ZOIP, the optimal product varieties (smart cameras) for distinct segments are determined by maximizing overall customer utility (OCU) and taking a firm's pricing policy into account.     

Modeling of transdisciplinary engineering assets using the design platform approach for improved customization ability

Original equipment suppliers (OES) that develop unique products are continuously faced with changing requirements during both the quotation and product development processes. This challenge is a different reality from companies that develop off-the-shelf products for the end consumer, which use fixed specifications and where product platforms have been a strong enabler for efficient mass customization. However, product platforms cannot adequately support companies working as OES. The reason is that a high level of customization is required which means that interfaces cannot be standardized, the performance is not negotiable, requirements are not initially fixed, and the specific system interacts with, is affected by, or affects other systems that are simultaneously developed in a transdisciplinary environment. The design platform (DP) approach provides a coherent environment for heterogeneous and transdisciplinary design resources to be used in product development by supporting both designing and off-the-shelf solutions. This research describes the introduction, application and further development of the DP approach at an automotive supplier to support the development of customized solutions when traditional modularity or platform scalability do not suffice. A computer tool called Design Platform Manager has been developed to support the creation and visualization of the DP. The support tool has a connection to a product data management database to link the platform model to the various kinds of engineering assets needed or intended to support variant creation. Finally, the support tool was evaluated by the case company representatives showing promising results.     

Virtual design of multiengineering electronics systems

The authors describe a virtual reality prototyping (VRP) and virtual product design approach that uses a modeling strategy to design, test, and evaluate concepts and products in advance-before creating any physical design models. Their design decisions reflect solutions and practices derived from systems engineering and software engineering research. Close competition has forced companies to focus on tailoring technological products to meet customer preferences in user interface design, usability, and appearance. Often, implementing new features has assumed less importance than creating an optimal product variation for different customer segments in international markets. Modern computer-based systems result from a multidomain development process, and organizing this work requires developers to communicate, cooperate, and coordinate effectively with nonengineering teams. Early linking of product development to other company operations supports this activity. Geographically dispersed development teams must communicate and coordinate effectively. Extending the use of interactive, functional, and photorealistic 3D product models into other company domains can facilitate effective business practices that cover the entire value chain, from simulated product idea to Web-based customer support of the final product. This wider adoption of the VRP technology and process offers ample scope for further research