Methodology for the Design of a Modular Process Structure Using Communality Matrices

Abstract

AbstractManufacturing companies face the challenge of fulfilling individual customer requirements while maintaining a low internal variety at the same time. In order to manage both the variety of products and the variety of production processes, companies increasingly focus on process modularization. Nevertheless, the conception of modular processes is a relatively new approach and sets challenges for manufacturing companies. This paper presents a methodology to design modular process structures, which integrates a market view, a product view and a process view, by using communality matrices. Therefore, similarities between different variants are indicated by a market-product communality matrix. Generic production processes and process variant drivers are identified and a product-process communality matrix is derived. Finally, the modular process structure is deduced from the communality matrices. The methodology supports companies to reduce resulting process-related complexity and therefore enhances internal efficiency in development and manufacturing.KeywordsProcess modularizationCommunality matrixProcess structure