Product portfolio map: a visual tool for supporting product variant discovery and structuring

Abstract

A fundamental criterion for reusing and continuously improving knowledge in product development is ensuring that the knowledge is explicit and visual. This paper is based on the situation of an engineer-to-order (ETO) manufacturing company, where historically grown product variety and related knowledge are diffuse (tacit). Consequently, several resources are used in (re)developing derivatives of previous products rather than innovating new ones. To establish a more competitive configure-to-order (CTO) product strategy, product knowledge needs to be revealed, systemized, and structured, and thus made explicit. Hence, product-specific knowledge and product variants have been analyzed and subsequently mapped at architectural, functional, and physical levels in one unified map and tested in the form of a proof-of-concept (POC) demonstrator with the introduced SME company. The result is a product portfolio map that forms a base for defining a systemized, transparent, unified product variant overview, which can be used as a basis for implementing a cross-variant product architecture and supporting knowledge-based approaches.

Keywords

Knowledge-based development (KBD) / Knowledge discovery / Product architecture / Product portfolio mapping

References

[1] Kumar S, Wellbrock J. Improved new product develop ment through enhanced design architecture for engineer-to-order companies. Int J Prod Res, 2009, 47(15): 4235-4254.

[2] Sanchez R. Creating modular platforms for strategic flexibility. Design Manag Rev, 2004, 15(1): 58-67.

[3] Shankar R, Mittal N, Rabinowitz S, Baveja A, Acharia S. A collaborative framework to minimise knowledge loss in new product development. Int J Prod Res, 2012, 51(7): 1-11.

[4] Wang KS. Towards zero-defect manufacturing (ZDM)—a data mining approach. Adv Manuf, 2013, 1(1): 62-74.

[5] Agard B, Kusiak A. Data mining for subassembly selection. J Manuf Sci Eng, 2004, 126(8): 627-631.

[6] Wang K. Applying data mining to manufacturing: the nature and implications. J Intell Manuf, 2007, 18(4): 487-495.

[7] Gupta A, Jain PK, Kumar D. A novel approach for part family formation using k-means algorithm. Adv Manuf, 2013, 1(3): 241-250.

[8] Stump B, Badurdeen F. Integrating lean and other strategies for mass customization manufacturing: a case study. J Intell Manuf, 2012, 23(1): 109-124.

[9] Kennedy BM, Sobek DK, Kennedy MN (2013) Reducing rework by applying set-based practices early in the systems engineering process. Systems Eng

[10] Bessant J, Caffyn S, Gallagher M. An evolutionary model of continuous improvement behaviour. Technovation, 2001, 21(2): 67-77.

[11] Kusiak A, Huang CC. Development of modular products. Compon Packag Manuf Technol, 1996, 19(4): 523-538.

[12] Agard B, Bassetto S. Modular design of product families for quality and cost. Int J Prod Res, 2012, 51(6): 1648-1667.

[13] Harlou U (2006) Developing product families based on archtectures. Dissertation, Technical University of Denmark

[14] Kuroda M, Mihira H. Strategic inventory holding to allow the estimation of earlier due dates in make-to-order production. Int J Prod Res, 2007, 46(2): 495-508.

[15] Ramesh B, Tiwana A. Supporting collaborative process knowledge management in new product development teams. Decis Support Syst, 1999, 27(1): 213-235.

[16] Gieskes JFB, Langenberg I. Learning and improvement in product innovation processes: enabling behaviors. Systems Eng, 2001, 4(2): 134-144.

[17] Nonaka I, Takeuchi H. The knowledge-creating company, 1995, New York: Oxford University Press

[18] Hines P, Holweg M, Rich N. Learning to evolve: a review of contemporary lean thinking. Int J Oper Prod Manag, 2004, 24(10): 994-1011.

[19] Sanchez R, Collins RP. Competing—and learning—in modular markets. Long Range Plan, 2002, 34(6): 645-667.

[20] Shook J. Managing to learn: using the A3 management process to solve problems, gain agreement, mentor and lead, 2008, Cambridge: Lean Enterprise Institute

[21] Nonaka I, Toyama R, Konno N. SECI, BA, and leadership: a unified model of dynamic knowledge creation. Long Range Plan, 2000, 33(1): 5-34.

[22] Mortensen NH, et al. Implementing a product platform in 35 man-days: the visual thinking approach. Int J Mass Cust, 2008, 2(3): 240-263.

[23] Colosimo BM, Poggi A, Tolio T. The tooling system configuration in a new manufacturing system architecture. Int J Prod Res, 2002, 40(15): 3779-3790.

[24] Mortensen NH, Hansen CL, Hvam L (2011) Proactive modelling of market, product and production architectures. In: The 18th international conference on engineering design, Copenhagen, pp 133–144

[25] Mortensen NH, et al. Modelling and visualising modular product architectures for mass customisation. Int J Mass Cust, 2008, 2(3): 216-239.

[26] Larsson F (2007) Managing the new product portfolio—an end to-end approach. Dissertation, Technical University of Denmark, Lyngby

[27] Patterson ML. Kahn KB. New product portfolio planning and management. The PDMA handbook of new product development, 2005, Hoboken: Wiley

[28] Simpson TW. Product platform design and customization: status and promise. AI EDAM, 2004, 18(01): 3-20.

[29] Haug A. Improving the design phase through interorgani sational product knowledge models. Int J Prod Res, 2012, 51(2): 626-639.

[30] Pimmler TU, Eppinger S (1994) Integration analysis of product decompositions. In: ASME design theory and methodlogy conference, Minneapolis, pp 343–351

[31] Steward DV (1991) Planning and managin the design of systems. Technology management: the new international language, Portland, pp 189–193

[32] Bruun HPL, Mortensen NH. Rivest L, Bouras A, Louhichi B. Visual product architecture modelling for structuring data in a PLMsystem. Product lifecycle management towards knowledge-rich enterprises, 2012, Heidelberg: Springer 598-611.

[33] Bruun HPL, Mortensen NH, Harlou U (2013) Interface diagram: design tool for supporting the development of modularity in complex product systems. Concurrent Engineering. doi: 10.1177/1063293X13516329

[34] Harlou U (2008) Developing product families based on architectures: contribution to a theory of product families. Dissertation, Technical University of Denmark

[35] Hvam L, Mortensen NH, Riis J. Product customization, 2008, Heidelberg: Springer

[36] Morgan JM, Liker JK. The Toyota product development system: integrating people, process, and technology, 2006, New York: Productivity Press

[37] Womack JP, Jones DT, Roos D (2007) The machine that changed the world: the story of lean production–Toyota’s secret weapon in the global car wars that is now revolutionizing world industry. Free Press; Reprint edition (March 13, 2007)

[38] Khan MS, Al-Ashaab A, Shehab E, et al. Towards lean product and process development. Int J Comput Integr Manuf, 2011, 26(12): 1105-1116.

[39] Welo T. On the application of lean principles in product development: a commentary on models and practices. Int J Prod Develop, 2011, 13(4): 316-343.

[40] Ulonska S, Welo T. New perspectives in the quest for unification of “lean” with traditional engineering design methodology. CIRP design conference, 2013, Bochum: Springer

[41] VDI2221 (1993) Methodik zum entwickeln und konstruieren technischer systeme und Produkte. VDI-Verlag, Düsseldorf

[42] Gershenson J, Prasad G, Zhang Y. Product modularity: definitions and benefits. J Eng Design, 2003, 14(3): 295-313.

[43] Ulrich K. The role of product architecture in the manufacturing firm. Res Policy, 1995, 24: 419-440.

[44] Da Cunha C, Agard B, Kusiak A. Design for cost: module-based mass customization. Autom Sci Eng, 2007, 4(3): 350-359.

[45] Agard B, da Cunha C, Cheung B. Composition of module stock for final assembly using an enhanced genetic algorithm. Int J Prod Res, 2009, 47(20): 5829-5842.

[46] Kristjansson AH, Hildre HP (2004) Platform strategy: a study of influencing factors. In: NordDesign conference, Tampere, pp 114–123

[47] Hansen CL et al (2012) Towards a clsssification of architecture initiatives: outlining the external factors.In: NordDesign 2012, Aalborg University, Aalborg

[48] Caux C, David F, Pierreval H. Implementation of delayed differentiation in batch process industries: a standardization problem. Int J Prod Res, 2006, 44(16): 3243-3255.

[49] Ivanović A, America P. Customer value in architecture decision making. Software architecture, 2010, Heidelberg: Springer 263-278.

[50] Hansen CL, Mortensen NH, Hvam L (2012) On the market aspect of product design: towards a definition of an architecture of the market. In: International design conference—design 2012, Dubrovnik, Croatia

[51] Huffman C, Kahn BE. Variety for sale: mass customization or mass confusion?. J Retail, 1998, 74(4): 491-513.

[52] Baldwin CY, Clark KB. Managing in an age of modularity. Harv Bus Rev, 2003, 75(5): 84-93.

[53] Cai S, Goh M, de Souza R, Li G. Knowledge sharing in collaborative supply chains: twin effects of trust and power. Int J Prod Res, 2012, 51(7): 2060-2076.

[54] Pahl G, et al. Konstruktionslehre, 2007, 7 Berlin: Springer

[55] Ulrich K, Eppinger S. Product design and development, 2004, Boston: Irwin McGraw-Hill

[56] Göpfer J. Modulare produktentwicklung—Zur gemeinsamen gestaltung von technik und organisation, 1998, Wiesbaden: Deutscher Universitätsverlag

[57] Ulonska S, Welo T (2012) A methodology for combining functional, principal and product structures applied to manufacturing technology development. In: IWAMA, Wang K, Strand-Hagen JO, Tu, Dawe, Trondheim, pp 139–146

[58] Sudjianto A and Otto K (2001) Modularization to support multiple brand platforms. Proceedings of DETC2001

[59] Mortensen NH et al. (2000) Conceptual modeling of product families in configuration projects. In: Workshop at the 14th European Conference on Artificial Intelligence, Berlin

[60] Cranefield S, Purvis M (1999) UML as an ontology modelling language 900

[61] van Veen E, Wortmann J. Generic bills of material in assemble-to-order manufacturing. Int J Prod Res, 1987, 25(11): 1645-1658.

[62] Kennedy MN. Product development for the lean enterprise, 2003, Richmond: The Oklea Press

[63] Baldwin C, Clark K. Braha D, Minai AA, Bar-Yam Y. Modularity in the design of complex engineering systems. Complex engineered systems, 2006, Heidelberg: Springer 175-205.

[64] Holland JH (1992) Adaption in natural and artificial systems. MIT Press, Cambridge

[65] Riitahuhta A, et al. Birkhofer H, et al. Open product development. The future of design methodology, 2011, London: Springer 135-146.

[66] Sosa ME, Eppinger S, Rowles CM. The misalignment of product architecture and organizational structure in complex product development. Manag Sci, 2004, 50(12): 1674-1689.

[67] Mankins JC (1995) Technology readiness levels. White Paper, 6 April

[68] Matta A, et al. A new system architecture compared with conventional production system architectures. Int J Prod Res, 2000, 38(17): 4159-4169.

[69] Henriksen B, Rolstadås A. Knowledge and manufacturing strategy—how different manufacturing paradigms have different requirements to knowledge. Examples from the automotive industry. Int J Prod Res, 2009, 48(8): 2413-2430.

[70] Haug A, Lisberg T, Hvam L. A software tool for design and documentation of configurator knowledge bases. Mass customization services, 2008, Kongens Lyngb: DTU Management 199-218.