Mass Customization Research Articles

A Reconfigurable Architecture for Industrial Control Systems: Overview and Challenges

The closed architecture and stand-alone operation model of traditional industrial control systems limit their ability to leverage ubiquitous infrastructure resources for more flexible and intelligent development. This restriction hinders their ability to rapidly, economically, and sustainably respond to mass customization demands. Existing proposals for open and networked architectures have failed to break the vicious cycle of closed architectures and stand-alone operation models because they do not address the core issue: the tight coupling among the control, infrastructure, and actuator domains. This paper proposes a reconfigurable architecture that decouples these domains, structuring the control system across three planes: control, infrastructure, and actuator. The computer numerical control (CNC) system serves as a primary example to illustrate this reconfigurable architecture. After reviewing open and networked architectures and discussing the characteristics of this reconfigurable architecture, this paper identifies three key challenges: deterministic control functionality, the decoupling of control modules from infrastructures, and the management of control modules, infrastructures, and actuators. Each challenge is examined in detail, and potential solutions are proposed based on emerging technologies.

The industrialization of additive manufacturing

AbstractOur world is constantly facing a wide variety of social challenges — currently, issues such as climate change, security, demographic change, and resource conservation are of significant importance and show an acute need for action. Among other things, disruptive technologies are needed to tackle such problems. Additive manufacturing (AM) is regarded as the ‘game changer/paradigm shift’ technology for the digital, automated production of the future — as the key enabler of ‘Production 2.0’. This sustainable and resilient technology enables new paths to innovative solutions across all industries through a high degree of individualization (mass customization) and great design freedom (‘manufacture for design’ instead of ‘design for manufacture‘). For example, internally cooled turbine blades for H2‐capable gas turbines, lightweight structures for more efficient aircraft or patient‐specific implants are only made possible by AM. In this way, AM makes an important contribution to solving the social challenges mentioned above now it is necessary to transfer this technology to board industrial use.

3D Printing with Self-Healing Materials and Applications

3D printing also called as the additive manufacturing. It is revolutionizing various industries by enabling the production of complex objects directly from digital models. This technology offers significant advantages over traditional manufacturing methods. Especially in reducing material waste and increased design flexibility. The range of 3D printing application contains healthcare to aerospace, reflecting its growing importance in modern society. Recently, 3D printing advancements have introduced in self-healing (SH) materials, it saved limitations related to the durability and repairability of printed objects. SH materials are categorized into external and internal systems. External SH materials use embedded healing agents that repair damage through chemical reactions, while internal systems rely on dynamic bonding within the material itself. This innovation not only extends the functional life of 3D printed items but also supports trends in mass customization and sustainability. This paper explores the mechanisms, types, and applications of SH materials in 3D printing, and mainly focus on their potential to enhance product longevity and functionality across medical, construction, and consumer goods sectors.

Research on Collaborative Strategy of Supply Chain Management under the Background of NIKE Mass Customization

Abstract: With the continuous advancement of technology and the popularization of the Internet, consumers' demand for personalized products is increasingly high. Traditional production modes have been unable to meet consumers' demands for product uniqueness and personalized experiences, which requires manufacturing enterprises to shift towards mass customization modes with unique advantages in production efficiency and cost control. Taking Nike as an example, this paper analyzes its supply chain problems based on its financial report. It then explores Nike's mass customization process using C2M and 3D printing, as well as information collaboration methods in the supply chain. Additionally, the paper analyzes AR-based virtual fitting technology and evaluates Nike's internal matrix organizational structure for customization and collaboration. From the perspectives of Nike's technology level and internal organizational structure, this paper analyzes the supply chain management and information collaboration process in its mass customization process, aiming to provide references for related manufacturing industries in enterprise operation and technology application during the mass customization process.

3D digital technology in upcycling apparel design: the creation of a modular redesign system and designer perspectives

ABSTRACT Despite advancements in sustainable apparel design, upcycling practices still face challenges limiting creativity and efficiency. This study develops a Modular Redesign System (MRS) using 3D digital technology to improve the upcycling process. The MRS was created with CLO3D and Aftereffects, producing ten redesign samples and demonstration videos. In-depth interviews with South Korean upcycling apparel designers were conducted to assess the system’s perceived effectiveness and explore key issues in upcycling design. The MRS involves four stages: Selection, Virtualisation, Virtual Ideation, and Construction and Fitting. Findings highlight the MRS’s ability to enhance ideation, reduce material waste, and save time and costs, offering practical solutions to current challenges in apparel redesign. The MRS also shows potential for mass customisation, serving as an effective communication tool for personalised upcycling services. This study bridges a gap in the literature by integrating 3D virtual simulation with modular design to advance sustainable and efficient upcycling practices.

Strategies Management for Mass Customization in the Apparel Industry: Case of Market Demand and Risk in China

With the development and adjustment of the industrial structure, the manufacturing industry, especially the transformation and upgrading of the apparel industry, is crucial for Chinas high-quality economic development. This paper studies the strategies of cooperation, consumer demand response, and risk identification and control in the mass customization market of the Chinese apparel industry. Firstly, it explores the co-creation strategies among enterprises in mass customization, analyzing cases of efficient resource allocation and cooperation in excellent apparel companies. Secondly, from the consumer behavior perspective, it studies how companies meet personalized needs through combined online and offline marketing models and brand positioning strategies. Finally, analyzing the supply chain, consumers, and internal aspects of enterprises, the risk factors in the mass customization market are identified, and corresponding pre-control measures are proposed. This study aims to provide management suggestions for apparel enterprises in the wave of mass customization, helping small to medium-sized enterprises (SMEs) face market challenges and improve operational efficiency and market competitiveness.

A mass customization framework and reclassification method for lower garments in E-commerce

A mass customization framework and reclassification method for lower garments in E-commerce

Mass customization using hybrid manufacturing and smart assembly: An optimal configuration and platform design approach

Hybrid Manufacturing (HM) and smart assembly stand as pivotal pillars in advanced smart manufacturing systems, offering manufacturers highly efficient and adaptable solutions for manufacturing. This paper delves into the configuration of a production line that integrates HM and assembly stages, each comprising multiple cells, with each cell housing one or more parallel stations. The objective is to manufacture a family of final assemblies, leveraging the platform concept to defer mass customization to later stages and thereby minimize processing costs. A mathematical programming model is proposed to identify the optimal configuration for such production lines, considering constraints such as an allowable capital cost and machine availabilities. In addition, the precedence, inclusion, and seclusion restrictions imposed on the part family are considered. The proposed mathematical programming model aims to delineate which HM features are processed in the part platform cell versus those processed in the mass customization (part variants) cells. Simultaneously, the model determines the components (variants from the HM stage) of final assemblies processed in the assembly platform cell, as well as components assembled or disassembled in the final assembly cells. Furthermore, the model seeks to determine the required number of stations in each cell to meet periodic demand. The overall objective of the model is to minimize the capital and the processing cost. A detailed case study illustrates the effectiveness of the proposed configuration approach and mathematical model. The proposed model is solvable in a few seconds by using commercial solvers.

Scalability enhancement in projection-based 3D printing through optical expansion

In the rapidly evolving field of additive manufacturing (AM), projection-based 3D printing emerges as a transformative solution to traditional manufacturing constraints. This study introduces a novel approach in projection-based 3D printing, utilizing a unique “infinity-corrected optical system” inspired by microscopy technology. The advanced optical system allows 3D printing to achieve performance comparable to multiple UV projectors while utilizing only a single UV light engine, offering a cost-efficient solution. This method enhances the print speed and expands the printable area, while maintaining the print resolution, addressing the shortcomings in existing 3D printing techniques. By employing a single UV projector along with integrated fixed optical components, this system offers a stable, reliable, and economically viable printing process. This innovation marks a pivotal advancement in mass production, mass customization, and large-area 3D printing, effectively bridging current technological gaps and paving the way for advanced manufacturing systems.

Process-structure–property study of 3D-printed continuous fiber reinforced composites

3D-printed fiber-reinforced composites hold many advantages compared to conventional composites in terms of individualization, mass customization, design freedom, and tailoring the composite geometry to load-bearing specifications. Among candidate continuous fibers for reinforcement, basalt fibers (BFs) serve as an eco-friendly alternative with excellent physical and thermal properties. However, the applicability of continuous BFs to be used for 3D-printed polymer composites was rarely addressed in existing literature. Especially, the effects of impregnation density during manufacturing and the influence of local fiber distribution on the fracture behavior of BF-reinforced composites remain unclear. In this study, a solution coating process was employed as a fiber pre-treatment to improve the packing density of BF in a polylactide (PLA) matrix. The effects of the resulting fiber volume fraction (8–31 %) and the local fiber distribution on the tensile fracture mechanisms of 3D printed BF/PLA samples are thoroughly analyzed using three-dimensional X-ray tomography. It was found that at a concentration of 3 wt-%, the coating solution uniformly dispersed optimally between the fibers, resulting in improved impregnation densities of the BF in the PLA matrix. Thus, the resulting composite exhibited a tensile strength of 175 MPa and a Young’s modulus of 6.2 GPa, respectively. A viscoelastic constitutive model incorporating damage is used for property prediction within a composite design framework to be applied to 3D-printed BF/PLA structures. The model is validated with experimental data from tensile tests. The obtained results demonstrate the applicability of eco-friendly BF/PLA composites for 3D printing of industrial high-performance applications with an individualized property profile.

Production-oriented approach for optimal mass-customisation of floor panel layouts in cross-laminated timber (CLT) buildings

PurposeThis study aims to develop a production-oriented approach for optimal mass-customisation of floor panel layouts in cross-laminated timber (CLT) buildings. The study enables meeting building clients’ unique floor plan requirements at an optimal cost and simultaneously enhances manufacturers’ profit by minimising material and manufacturing process waste.Design/methodology/approachThe present research uses a hybrid approach consisting of field data collection, mathematical modelling, development of a Genetic Algorithm (GA) and scenario analysis. Field data includes engineered timber production information, design data and building code requirements. The study adopts the Flexible Demand Assignment (FDA) technique to formulate a mathematical model for optimising the design of mass timber buildings and employs GA to identify optimal production solutions. Scenario analysis is performed to validate model outputs.FindingsThe proposed model successfully determines the load-bearing wall placement and building spans and specifications of floor panels that result in optimal production efficiency and the desired architectural layout. The results indicate that buildings made of a single category of thickness of panels but customised in various lengths to suit building layout are the most profitable scenario for CLT manufacturers and are a cost-effective option for clients.Originality/valueThe originality of the present study lies in its mathematical and model-driven approach towards implementing mass customisation in multi-storey buildings. The proposed model has been developed and validated based on a comprehensive set of real-world data and constraints.

Development and construction of a mechanized moving platform for human service

The purpose of the proposed article is the development and construction of a mechanized mobile platform for serving people, which is caused by the need to increase the safety of the operation of such technical means, in particular, in the case of the need for mass customer service. The methodology is based on search, research and creative approaches. The methods of development analysis, patent search, synthesis of technical solutions, simulation modelling was used. Scientific novelty. The study of the features of various approaches to the creation of effective mechanized moving platforms, the analysis of solutions and the dynamics of patenting made it possible to substantiate the directions of development of technical solutions and the prospects of developments. The authors proposed constructive solutions for mobile platforms, developed approaches to the technical implementation of increasing the safety of their operation, proposed energy-saving approaches aimed at reducing the energy consumption of mechanized means, which is especially relevant in the mass implementation of platforms for serving people. Research results. The article solves important safety issues of human service, in particular in the entertainment industry through the development of structural parts, drives and rules for the operation of mechanized moving platforms. Synthesized constructive solutions obtained in the course of patent research, analysis of modern technical solutions, rational technical design, and expert evaluation are presented. It was determined that the safety of the operation of mechanized moving platforms, which are intended for the transport of people in the field of tourism, depends on effective approaches to the design and components of the technical system in the form of a moving platform, its structural components, elements of its mechanism and the drive system as a whole, which with the optimization of technical indicators the stability of the overall system, the smoothness of movement and braking of the platform, the optimization of the materiality of the structure in total allow to have a qualitative effect on improving the safety of human operation.

Technologies for customized housing in modular construction

In the modular construction, the range of customization options is limited compared to traditional construction, which can be seen as a negative aspect. Different customization strategies can be adopted by companies, but the choice of the appropriate strategy is related to the technologies used in the operational process, with emphasis on the design and production stages. This study aims to compare the technologies used in the design, production and exchange of information in the development of customized housing in modular construction companies in Brazil and England. To achieve that, three case studies were conducted in English modular construction companies operating in the residential sector. The results of the case studies were compared with the literature on technologies used by Brazilian companies. It was noted that English companies, regardless of their size and type of customization offered, use Revit software to develop the design, and communication between different designers is done via cloud computing. However, communication between designers and production is often done on paper, which leads to errors. The machinery used on the shop floor varies between companies. The results found are similar to the Brazilian reality. It was noted that companies do not make use of all available potential; however, larger companies that are able to perform mass customization invest more in technologies for control and integration between operations. To ensure greater productivity and efficient use of technologies, companies should adopt mass customization.

Unlocking the potential of low-melting-point alloys integrated extrusion additive manufacturing: insights into mechanical behavior, energy absorption, and electrical conductivity

AbstractAdditive manufacturing is a commonly used manufacturing method in complex part fabrication, instant assemblies, part consolidation, mass customization and personalization, on-demand manufacturing, lightweight, and topological optimization due to its advantage of lower costs, flexibility to learn and use, reduced raw material wastage, digital design integration, high efficiency, environmental-friendliness. However, the current metal 3D printing, which is mainly fabricated layer by layer using laser, is expensive to manufacture metal parts. Therefore, in this paper, a low-cost high-quality metal manufacturing process called low-melting-point alloys (LMPAs) integrated extrusion additive manufacturing will be examined. This manufacturing process can fabricate complex metal structures and integrated circuits with simple fused deposition modeling, which is a cost-effective method for producing these objects. LMPAs with different melting points are used for performance comparison to find out the optimized mechanical behavior, energy absorption properties, and electrical conductivity. Our investigation into LMPAs integrated extrusion additive manufacturing has revealed significant findings. Tensile tests conducted on LMPAs with varying melting points have illuminated distinct mechanical behaviors. Notably, lower melting points contribute to increased ductility but reduced stiffness, while higher melting points result in greater stiffness but diminished ductility. These results emphasize the importance of tailoring LMPA selection based on specific application requirements. Furthermore, our examination of lattice and triply periodic minimal surface structures has demonstrated consistent energy absorption properties across different manufacturing temperatures, highlighting the adaptability and versatility of LMPAs for energy absorption applications. Additionally, our electrical conductivity assessments have shown that LMPAs with melting points of $${{47}^{\circ }C}$$ 47 ∘ C and $${{120}^{\circ }}\hbox {C}$$ 120 ∘ C exhibit higher electrical conductivity, making them suitable for applications requiring good electrical conduction properties. These findings collectively underscore the significance of LMPAs in additive manufacturing, offering valuable insights for material selection and applications in various domains.

The Influence of the Assembly Line Configuration and Reliability Parameter Symmetry on the Key Performance Indicators

In the context of the demand for mass customization of products, a trade-off between highly efficient automated systems and flexible manual operators is sought. The linear arrangement of workstations made it possible to divide the process into many simple operations, which increases production efficiency, but also results in an increase in the number of workstations and a significant extension of the line. A human operator is usually treated as a quasi-mechanical object, and a human error is considered, similarly, as a failure of a technical component. However, human behavior is more complex and difficult to predict. A mathematical model of a new production organization is presented, including dividing the traditional production line into shorter sections or replacing the serial assembly line with a U-line with cells. Moreover, the reliability of operator and technical means are distinguished. Work-in-progress inventories are located between line sections to improve system stability. The stability of the assembly line is examined based on the system configuration and probabilistic estimates of human failure. The influence of the symmetry of reliability parameters of people on key performance indicators (KPI (headcount), KPI (surface) and KPI (Overall Equipment Effectiveness) is examined. KPI (solution robustness) and KPI (quality robustness) are also presented in order to evaluate the impact of a disruption on the assembly line performance. New rules for assigning tasks to stations are proposed, taking into account the risk of disruptions in the execution of tasks. For comparison of assembly problems, heuristic methods with newly developed criteria are used. The results show the impact of symmetry/asymmetry on assembly line performance and an asymmetric distribution of manual assembly times that is significantly skewed to the right due to human errors. On the assembly line, the effects of these errors are cumulative and lead to longer assembly times and lower KPIs.

Influence of printing parameters on the mechanical behavior of 3D-printed SS316L parts manufactured using laser hot wire directed energy deposition

Hybrid manufacturing combines the simultaneous benefits of additive manufacturing (complex geometries, part consolidation, and mass customization) with the advantages of subtractive manufacturing (superior surface finish and enhanced dimensional accuracies) by integrating a suite of complementary traditional processes into a base platform of additive manufacturing. The use of hybrid technology has grown in recent years given its capabilities on repairing metallic structures, producing parts with conformal cooling features, and manufacturing functionally graded products. These kinds of capabilities are of great interest to the medical implant, energy, automotive, maritime, and aerospace industry sectors, among many other fields. This work investigated the mechanical properties of stainless steel (SS) 316L as a function of different tool paths strategies using an integrated 5-axis CNC hybrid Mazak system with a laser hot wire deposition system (LHWDS). This study includes the evaluation of different printing parameters and their impact on the quality of the printed bead as well as the incorporation of a structure–property material relationship based on the mechanical performance of the manufactured coupons.

Determinants of online apparel mass customization: a decade in review

PurposeMass customization is a production process that allows consumers to customize products from an array of options to suit their preferences and needs and benefit from large-scale production efficiencies. In recent years, several apparel retailers have integrated customization into their online presence. While the benefits of online apparel mass customization (OAMC) are apparent, factors that determine the usage of the process are many. Therefore, it is important to explore these factors and understand the relationships between them and the impact on the intention to use OAMC.Design/methodology/approachA review of studies published in the last decade was conducted through the Scopus, Web of Science and JSTOR databases in September 2023. Peer-reviewed research articles published in the English language were included. These studies were carried out in the United States of America, Canada, Korea and China and addressed motivations and antecedents of OAMC technology.FindingsThe data were extracted, and the findings were synthesized. The review process enabled us to examine several theories and determinants of OAMC. The latter were categorized into the following themes: “consumer personality and psychology”, “consumer perceptions”, “consumer behaviour determinants” and “process, experience and product”. The influence of consumer personality traits, psychogenic needs, characteristics and other facilitating conditions emerged through the review.Originality/valueThe purpose of this paper is to study the various determinants of OAMC and thereby provide valuable information to businesses in OAMC domains to improve customized processes, understand consumers' motivations and develop marketing strategies that improve overall satisfaction with OAMC.

Flexible assembly job shop scheduling problem considering reconfigurable machine: A cooperative co-evolutionary matheuristic algorithm

With popularity of mass customization, enterprises urgently need to improve reconfigurability to handle rapidly changing market demands. Reconfigurable machines have been widely applied in the flexible assembly job shop. These reconfigurable machines can be equipped with various and limited auxiliary modules (AMs) to provide multiple alternative functions to manufacture numerous products. Therefore, this study addresses flexible assembly job shop scheduling problem considering reconfigurable machines with limited AMs to minimize makespan. First, a mixed-integer linear programming (MILP) model is formulated to define the problem. Then, a cooperative co-evolutionary matheuristic algorithm (CCMA) is presented to efficiently tackle large-scale FAJSP-RM problem. In this algorithm, a MILP-based evolution method, which relies on a decomposed MILP (D-MILP) with known sequence decisions, is proposed to explore the optimal machine and AM assignments. Meanwhile, a collaborative initialization and dual collaborative strategy are proposed to improve the performance of the proposed CCMA. Comprehensive experiments are conducted on 720 instances, extended from the well-known Fdata and BRdata benchmarks, to evaluate the proposed MILP model and CCMA algorithm. The results illustrate that the MILP model can produce optimal solutions for small-scale instances. The MILP-based evolution method improves the performance of the CCMA algorithm by 12.63, and the CCMA outperforms other well-known algorithms from numerical, statistical, differential and stable analysis.

The need for individualization: An open innovation perspective on the case for customized products

In modern marketing, the emergence of mass customization has reoriented the focus from traditional marketing practices toward a customer-centric approach. The individualization feel among consumers and the innovative approach taken by businesses are currently evident in the market but has yet been holistically analyzed. This study applied a modified Theory of Planned Behavior by incorporating the need for individualization, hedonic and utilitarian motivations, with a 4Ps marketing mix – with the main objective to identify factors contributing to the intention to make purchase of customized products. The survey involved 311 participants who completed an online questionnaire utilizing purposive sampling approach, focusing on those who had previously bought customized products. Structural Equation Modeling was employed as a statistical method to analyze the data with SPSS AMOS v25. Findings revealed that the need for individualization proved to have the highest effect on the intention to purchase customized products, explaining that consumers who are strongly inclined toward individualization not only perceive greater value in customized products but also express a higher intention to purchase them. This was followed by its direct significant effect on attitude, with an even higher effect on perceived behavioral control, along with the marketing mix latent variable and customer perceived value on purchasing intention. This study offers valuable insights for retail brand management and provides potential strategies for business improvement. Moreover, a valuable contribution to the limited literature on the promotion of customized product purchases was identified. Lastly, the developed framework and implications may be applied and extended by future research in the consumer behavior field.

User Communities: The Missing Link to Foster KIBS’ Innovation

In today’s knowledge-driven economy, collaboration among stakeholders is essential for the framing of innovative trends, with knowledge-intensive business services (KIBS) playing a core role in addressing market demand. Users’ involvement in shaping products and services has been considered in innovation ecosystem frameworks. Fewer risks in service/product development, and more sustainability and market acceptance, are a few of the benefits arising from including the user community (UC) in innovation partnerships. However, the need for resources, absorptive capacity and tacit knowledge, among other capabilities, is often a reason for overlooking this important contributor. KIBS possess a vast knowledge base, cater to digital tools, and mediate and propel innovation with different partners, benefiting from exclusive cognitive proximity to remix extant knowledge with emergent information from communities into new products and services. The aim of this study is to assess and quantify the effect of the collaboration with UC through three active forms of collaboration (co-creation, mass customization, and personalization) on different innovation types developed in KIBS. The significance of the user community was proven across all innovation types. Robustness analysis confirmed the results for both P-KIBS and T-KIBS. P-KIBS may be better suited to co-creation policies for product and service innovation, personalization of processes, and organizational and marketing innovations. T-KIBS can focus on mass customization, ensuring good innovation success. Additionally, co-creation with user community is best for product innovation.