Integration of the Design Structure Matrix (DSM) and Modular Function Deployment (MFD) methods applied to mass customization aiming product modularization: a case study on heavy vehicle suspension

Abstract

This work presents the integration between the Design Structure Matrix (DSM) and Modular Function Deployment (MFD) methods applied to the modularization process of an air rear suspension system for heavy vehicles with 44 components by a cross-functional team. These two methods possess desired characteristics to process in industries, such as matrix-based data entry and commercial and academic software available. The modularization process started with the DSM method base on a binary square matrix that shows the presence or absence of relationships between pairs of components in a system. A DSM algorithm reordered the binary square matrix elements to generate the preliminary modules. That way, 26 from 44 components were grouped into eight modules that became new components, reducing the initial number of components from 44 to 26 (44-26+8). The reduction of the number of components made easy the application of the MFD method. The MFD method incorporated the customer requirements using the Quality Function Deployment (QFD), the Engineering point of view utilizing the Design Property Matrix (DPM), and the strategies of the company employing the Module Indication Matrix (MIM) in the modularization process. The QFD Matrix, DPM, and MIM union form the Product Management Matrix (PMM). A dendrogram helped the cross-functional team visualize the hierarchical relationship between the DPM and MIM components and analyze the modules' set. The cross-functional team chose seven final suitable modules considering components mounting in the assembly line and the supply chain of components too. This systematic modularization process showed up efficiently and made the work of the cross-functional team easy. Finally, the cross-functional team suggested the company board invest in knowledge management tools to assist the future cross-functional teams in replicating this modularization process in other heavy vehicle systems.