From Integral to Modular : A Case Study in Production System Development with a Simulation Perspective

Abstract: In the pursuit of excellence industrial companies are increasingly employing production system development to rationalize their processes. One such approach that has been employed to great extend in the automotive industry is that of introducing modularity to the product design. This shift from integral products to modular ones, is associated with a higher level of standardization of parts and processes. However, researchers are still mapping out this correlation. As the connection between modularity and the recorded effects is still up for discussion, still fewer studies have been made on how to most effectively adopt modularisation. This thesis is therefore a research that explores the relationship between product design and production from a perspective of production system development. It is a collaborative study conducted with a manufacturer of industrial robots that is preparing to transition from an integral product design to a modular one. The case study utilizes discrete – event simulation to model the impact of such a changeover in the production system. Not resulting in a step-by-step how-to guide, the study nevertheless shows that discrete – event simulation can prove to be a valuable asset both when analysing what-if scenarios and when pinpointing pre-emptive measures in order to mitigate any negative disruption such a transition might initially bring.