Machine Modularity Addresses Mass Customization

Summary

Interfaces are a vital component of modularization. But do machine builders have to adhere to specific standards?

One of the most significant challenges manufacturers face is: How do I serve the very special and unusual wishes of consumers? As things stand today, this would appear to apply only to makers of consumer packaged goods and other consumer products, such as automobiles and appliances. But the current trend toward factoring in individual customer wishes has consequences that extend deep into production technology choices. Original equipment manufacturers (OEMs) and their suppliers must consider the trend of mass customization.

The scope and degree of individualization as it is currently strived for can no longer be achieved with the tool kit of conventional mass production, but calls for a completely different design of production processes, including machines and systems. The individualization of mass production is one of the core aspects of Industry 4.0. The resulting challenge for the manufacturers of production systems is as follows: How should the necessary equipment and processes for “individualized production” be shaped and designed so that the costs will not explode and the resources required will not rise sky high?

KUKA, a robot manufacturer, has formulated an answer: “The key [to mass customization] lies in a high degree of standardization and automation, which at the same time affords scope for variations of customer-relevant product features. What is more, the concept of modularization, which provides customers specific, tailored product configurations based on a modular building block system, is a cost-effective way to meet individual customer needs.” This results in three central perspectives for OEMs:

• the shift toward individualized serial customization
• modularization as the key, in combination with automation and standardization
• preservation of latitudes for the variation of customer-specific product features

This perfectly describes the conflicting demands made on OEMs in the mechanical and plant engineering sector. The dilemma is very reminiscent of the statement ascribed to the philosopher Hegel, “Freedom is the insight of necessity.”

Importance of interfaces

Interfaces are a vital component of modularization. But do they always have to adhere to certain standards? The increasing automation and modularization of production systems has technical and business advantages for both OEMs and end users. As the degree of automation rises and modularization deepens, however, it is precisely the interfaces that play an increasingly decisive role as the link between the elements or modules. This is because the following holds true: The interfaces do not determine the entire modularity, but, without interfaces, the modules will never become a whole.

This will be further differentiated, because in some instances standardized interfaces will be more advantageous and in others “individualized” interfaces will be more advantageous. The importance of customer-specific product definitions for OEMs in the mechanical and plant engineering sector can be well illustrated, as shown in the left side of the figure 1 diagram. The possible degree of product individualization by the end user is related to the life cycle of production systems. The further the cycle progresses, the smaller the remaining scope for individualization is (transition from “hard” to “soft customization”).

Deciding on individual interfaces

My company provides solutions for all electromechanical interfaces required in modern control, drive, human-machine interface, and communication technology for production systems at work in all branches of industry. Analyzing current customer applications, we have come up with the following advice for the individualization of interfaces based on the above-described function groups (right side of Figure 1):

1. Generally speaking, it makes sense to use individualized or customer-specific electromechanical interfaces for the functional groups, which largely represent the core OEM know-how.

2. Customer-specific, tailored interfaces are most often used for those modules and aggregates that are developed or manufactured directly by the respective manufacturer. This applies to all degrees of product individualization in mechanical engineering, from “soft customization” through the various stages of “hard customization,” to one-of-a-kind productions.

3. With regard to sensors and actuators, the typical interfaces for the respective industry sector are usually chosen. Trendsetters and innovators, however, do try to set themselves apart from the market by deploying specific, tailored interfaces.

4. When it comes to data interfaces, machine manufacturers rely entirely on standardized solutions. This applies both to the industrial bus and Ethernet connections employed and to all other forms of digital data transmission.

What are the main reasons behind the design of the interfaces? In terms of data transmission, it is evident that both Industrial Ethernet and bus systems in the manufacturing area and the higher-level data interfaces are subject to tremendous change. The technologies deployed are largely determined by the suppliers of the control components. Therefore, the recommendations for production-system OEMs are twofold: 

• As far as possible, these interfaces should follow the latest standards of the control technology employed and ensure the modularity and scalability of the machines and systems.
• With regard to interfaces beyond the machine edge, such as those for connection to higher-level systems, the interfaces should always represent the advanced state of the art.

• End user requirements for companies that operate specific production lines and want to consciously differentiate themselves from individual suppliers or focus on them.
• Differentiation vis-à-vis competitors in the expansion of business models to offer after-sales, service, and similar services aimed at a long overall life cycle of production systems. Individualized interfaces allow these services to be controlled and expanded in a user-friendly manner.
• Intentionally nonstandard design of machine interfaces or equipping technology with specific interfaces in order to stand out from the competition. In particular, OEMs that perceive themselves as technology leaders, innovators, or trendsetters are taking advantage of these opportunities.
• Use of sensors, actuators, or their combination developed according to specific specifications of individual manufacturers. In these instances, too, the protection of one’s own know-how is the strongest motive for leveraging individualized interfaces.

Customizing electromechanical interfaces to meet even the most unusual OEM requests is increasingly possible. Depending on the degree of individualization required, modular design principles applied to connector products can provide convenient scalability and minimal customization. At the highest level of “hard customization,” however, customer-specific interfaces can be developed to meet individual customer requirements. This range allows OEMs to cost effectively meet even the most unusual customer wishes in mechanical and plant engineering.

This article was originally published in InTech's July/August issue.