Modularization of an Existing Product Family
Siivonen, Pauli (2015)
Siivonen, Pauli
2015
Konetekniikan koulutusohjelma
Teknisten tieteiden tiedekunta - Faculty of Engineering Sciences
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Hyväksymispäivämäärä
2015-09-09
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201508271539
https://urn.fi/URN:NBN:fi:tty-201508271539
Tiivistelmä
This Master of Science Thesis was made for Cargotec Oy. Variability of products and the different customer needs have increased the amount of part numbers that have to be maintained. This thesis seeks to find a solution for the problem. The aim of the thesis is to demonstrate how an existing product family can be modularized.
Modularity has been studied a great deal in recent years and a number of different methods have been developed for modularizing product structures. This thesis introduc-es the Design Structure Matrix, Function Heuristics and Modular Function Deployment methods. The study of these methods, however, indicates that none of these are suitable as such for the modularization of an existing product family. The Brownfield Process is studied in more detail, because it is developed specifically for the modularization of existing product families.
The thesis works as an instruction manual for the case company, in which modulariza-tion is explained and the different steps of the Brownfield Process are clarified in detail. The Brownfield Process was applied to the case company’s products and a proposal on how the company could modularize their product family was created. In the example case the existing product structures were analyzed and the customer requirements, which cause the need for variation in the products, were studied.
Good results were obtained in the example case, even though the scope of the case was focused on a limited number of crane models and structures. By applying of the process the part numbers could be reduced significantly. Also other benefits for the company could be obtained. During the example case some problems arose, which must be taken into account during a modularization project. The cooperation with the various experts in the company turned out to be very important. The process requires a great deal of information on products, product structures, design principles and customers. The com-pany’s marketing, sales and engineering teams have to participate in the process.
It was also noticed, that by modularization alone, long-term benefits cannot be achieved. The company has to make sure, that the manufacturing of the products is made in a way that benefits from modularity. The sales persons have to be trained to sell modular products as well. In order to make sure, that the modular product structure is maintained in the future, the company has to have a certain person or group who owns the modules and interfaces. Their tasks include, for example, ensuring that changes in the products do not violate the modularity.
Modularity has been studied a great deal in recent years and a number of different methods have been developed for modularizing product structures. This thesis introduc-es the Design Structure Matrix, Function Heuristics and Modular Function Deployment methods. The study of these methods, however, indicates that none of these are suitable as such for the modularization of an existing product family. The Brownfield Process is studied in more detail, because it is developed specifically for the modularization of existing product families.
The thesis works as an instruction manual for the case company, in which modulariza-tion is explained and the different steps of the Brownfield Process are clarified in detail. The Brownfield Process was applied to the case company’s products and a proposal on how the company could modularize their product family was created. In the example case the existing product structures were analyzed and the customer requirements, which cause the need for variation in the products, were studied.
Good results were obtained in the example case, even though the scope of the case was focused on a limited number of crane models and structures. By applying of the process the part numbers could be reduced significantly. Also other benefits for the company could be obtained. During the example case some problems arose, which must be taken into account during a modularization project. The cooperation with the various experts in the company turned out to be very important. The process requires a great deal of information on products, product structures, design principles and customers. The com-pany’s marketing, sales and engineering teams have to participate in the process.
It was also noticed, that by modularization alone, long-term benefits cannot be achieved. The company has to make sure, that the manufacturing of the products is made in a way that benefits from modularity. The sales persons have to be trained to sell modular products as well. In order to make sure, that the modular product structure is maintained in the future, the company has to have a certain person or group who owns the modules and interfaces. Their tasks include, for example, ensuring that changes in the products do not violate the modularity.