A two-phase methodology for modular product customisation

Mass customisation is known as producing customised products while entailing the efficiency of mass production. The proposed model is based on manufacturing features and entails the concept of modular design. That is, manufacturing features are identified and analysed in a way that enables the generation of what is called 'manufacturing core'. Manufacturing cores are generated through two phases of optimisation. The first phase is known as product's manufacturing features analysis which includes starting features identification. The second phase is known as manufacturing cores formation that ends with generation of manufacturing cores. A case study is proposed as an implantation of the model on real products (flanges). This approach comes as intermediate production strategy between make to stock and make to order strategies. It provides a decision tool for managers to better identify which strategy is better to use. The model proposes an integrated manufacturing cores and modular design approach. Therefore, lower inventory of sub-assemblies and components are planned for a more efficient production operation. [Received 02 March 2010; Revised 10 November 2010; Accepted 25 January 2011]