An Approach to Integrated Modularization

AbstractA modular architecture is a strategic means to deliver external variety (to the customers) and internal commonality (to the manufacturing organization). A common view is that a module should be a physical and functional building block, with well-defined and standardized interfaces between modules, and that it should be chosen for company specific reasons. Existing methodologies, such as Modular Function Deployment with the Modular Indication Matrix (MIM) representation of identified company-specific module drivers, can be used to assist the task to identify modules. Other approaches, such as clustering of the Design Structure Matrix product representation, may be used to identify modules from a technical complexity point of view. A new methodology for product modularization that integrates technical complexity and company strategies is proposed in this paper. The core of the presented methodology is to adapt the component-DSM with MIM-strategies, before clustering this hybrid representation with the previously presented IGTA++ clustering algorithm. The proposed methodology is exemplified and logically verified with an industrial test rig modularization case. The modular test rig architecture chosen with the new methodology is shown to have 53% less complexity, as defined by Pugh, compared with the original architecture, and it could potentially reduce the risk of design mistakes, and reduce the development time by up to 70%. It is also estimated that it would be possible to reuse up to 57% of the modules, in future test rig redesign projects, which indicates potentially large savings in cost and development time