Framework for Configuration of Customizable Industrial Machine

Abstract

In today's global machine industry, companies face challenges of balancing high product variety with operational efficiency. In high-variety manufacturing, the challenge of managing diverse product offerings can lead to exponential complexity growth if configuration logic remains undocumented; consequently, the organizational ability to fulfil orders becomes dependent on the specialized expertise of personnel rather than scalable, system-based processes. To maintain competitiveness and accelerate time-to-market, manufacturers are shifting toward modular product architectures that decouple growth from organizational complexity. This thesis examines the modularization and standardization of a heavy equipment product portfolio—specifically focusing on the structural duality of two product lines within one product family. The objective of the study was to identify systemic deficiencies in the current configuration process and define a structured path toward a modular process using the Brownfield Process (BfP) framework. The research utilizes internal project data, workshop notes, and PLM system analysis as primary materials, grounded with modularity theories. The results of the study reveal an information gap in the company's current state. Quantitative analysis identified a multiplication of variants, showing that the high volume of project-specific designs masked the actual commonality of core components. The research concludes that the lack of formalized configuration knowledge and standardized interfaces neutralizes the benefits of engineering efforts toward commonality. To address this, the work proposes a transition to an interface-driven architecture where functional changes are contained within defined Change Zones, allowing for a unified solutions across the entire portfolio. The thesis recommends the implementation of a Brownfield process for both the potential future development project and the current generation of machines and to map configuration rules. The target process ensures that customer specifications are systematically translated into technical structures, significantly improving the efficiency of current processes and securing the intended competitive advantages of a module system.