Sustainability 15 00910 v4

sustainability
Article
Modular Product Architecture for Sustainable Flexible
Manufacturing in Industry 4.0: The Case of 3D Printer and
Electric Toothbrush
Tufail Habib 1 , Muhammad Omair 1 , Muhammad Salman Habib 2 , Muhammad Zeeshan Zahir 3, * ,
Sikandar Bilal Khattak 4 , Se-Jin Yook 5, * , Muhammad Aamir 6 and Rehman Akhtar 4
1 Department of Industrial Engineering, Jalozai Campus, University of Engineering and Technology (UET),
Peshawar 25000, Pakistan
2 Department of Industrial & Manufacturing Engineering, University of Engineering and Technology (UET),
Lahore 54890, Pakistan
3 Department of Mechanical Engineering, University of Engineering and Technology (UET),
4 Department of Industrial Engineering, University of Engineering and Technology (UET),
5 School of Mechanical Engineering, Hanyang University, Seoul 04763, Republic of Korea
6 School of Engineering, Edith Cowan University, Joondalup 6027, Australia
* Correspondence: zeeshan.zahir@uetpeshawar.edu.pk (M.Z.Z.); ysjnuri@hanyang.ac.kr (S.-J.Y.)
Abstract: Integrating sustainability, a flexible manufacturing system, and Industry 4.0 resolves the
issues of fluctuating market demand arising from customization requirements. Modular products
allow flexibility to adapt to changing requirements and optimize resource utilization. In this study,
a method was proposed and applied to two products, i.e., a 3D printer and an electric toothbrush
featuring modular architecture, multiple product versions, and customization, to contribute to the
development of sustainable flexible manufacturing systems. From the results of the two case studies
Citation: Habib, T.; Omair, M.; Habib, nine modules were identified that contain specific functions and related interface information. From
M.S.; Zahir, M.Z.; Khattak, S.B.; Yook, these modules, one platform was developed that comprises common entities used in all variants of the
S.-J.; Aamir, M.; Akhtar, R. Modular products. This platform was further extended to product families. From the modules, product archi-
Product Architecture for Sustainable
tecture was developed that supports the product and process relationships. These relationships can
Flexible Manufacturing in Industry
be developed concurrently, enabling product features to be linked to the manufacturing setup. Thus,
4.0: The Case of 3D Printer and
when a modular architecture is developed, the factory has to be reorganized accordingly, or reconfig-
Electric Toothbrush. Sustainability
uration is possible. Hence, the main aim of the research was to develop modular product architecture
2023, 15, 910. https://doi.org/
10.3390/su15020910
to identify product and process relationships for a sustainable flexible manufacturing system.
Academic Editors: Claudio Favi, Keywords: mass customization; modular product architecture; sustainable flexible manufacturing
Marco Marconi and Malgorzata
system; Industry 4.0; module indication matrix
Jasiulewicz-Kaczmarek
Received: 13 October 2022

Revised: 22 December 2022
Accepted: 30 December 2022 1. Introduction
Published: 4 January 2023 Since the first industrial revolution, established manufacturers have wished to sat-
isfy the increasing customer demand without compromising the fast-depleting natural
resources [1]. However, over the years, the world has moved from mass production to
customized production and is currently in the era of personalized production [2]. As a re-
Copyright: © 2023 by the authors.
sult, manufacturers must respond quickly and with greater flexibility. The modular design
Licensee MDPI, Basel, Switzerland.
This article is an open access article
satisfies the changing customer requirements and cost constraints [3]. Moreover, modular
distributed under the terms and
and reconfigurable products can enhance the flexibility and acceptability of Industry 4.0 [4].
conditions of the Creative Commons
The core idea of Industry 4.0 is to use emerging technologies in a way that business and en-
Attribution (CC BY) license (https:// gineering processes are deeply integrated, making production operate in a flexible, efficient,
creativecommons.org/licenses/by/ and sustainable way with consistently high quality and low cost [5].
4.0/).
Sustainability 2023, 15, 910. https://doi.org/10.3390/su15020910 https://www.mdpi.com/journal/sustainability

Sustainability 2023, 15, 910 2 of 29
The term “Industry 4.0” was coined in Germany in 2011 and used for the next industrial
revolution aiming for the digitalization of the manufacturing industry. This digitalization
was brought by Industry 4.0 strategies by creating automation with software and connect-
ing all the processes in the manufacturing setup. With this strategy, businesses will establish
global networks using their machinery, production facilities, and warehousing systems in
the cyber-physical systems (CPS). These CPS in the manufacturing environment include
smart machines, storage systems, and production facilities capable of autonomously ex-
changing information and controlling one another. This leads to significant benefits in
the manufacturing, supply chain, material utilization, and product life cycle management
processes [6]. It is worth noting that sustainability is a major global issue, and ignoring
it might lead to financial losses [7]. Therefore, digitization has been the key enabler for
sustainability and sustainable development and is the building block of Industry 4.0 [8].
Modular product architectures enable mass customization by allowing a large range
of goods to be built and assembled. Hence, modularity can be employed in goods
(product architectural designs), manufacturing processes, and logistics (supply chain
configuration) [9,10]. Product architectures that use standardized interfaces in both hard-
ware and software allow for the effective implementation of mass customization and related
manufacturing strategies [11]. It is worth noting that product architecture refers to how
a product’s functional parts are organized into physical units and how they interact. A
module is a physical or conceptual grouping of components, and modularity is the concept
of breaking down a system into independent portions or modules that can be regarded as
logical entities in both hardware and software [12].
Modularity is also a business approach aiming for a flexible product architecture
that allows companies to quickly develop, produce, and market new products to mass
customization and personalization [13]. Furthermore, a module is a specification entity
containing a specific function and related interface information, any module variant carries
relevant information in the value chain, such as in sales, engineering, supply chain, and
production [14]. Following this approach, modularity creates system information on
different business levels to support Industry 4.0 or smart manufacturing in a reliable
way. Software modularity is the decomposition of a program into smaller programs
with standardized interfaces and it has the same definitions as hardware modularity [12].
Software modules are based on different functions required by customers with standardized
interfaces, i.e., to allocate different functions to software modules and then implement them
in software code. In addition, the choice of product architecture has broader implications
in design and manufacturing [15].
The process of converting system-level specifications into component-level specifi-
cations is known as system architecting [16]. The breaking down of complex products,
assemblies or large engineering systems into smaller subsystems can be managed easily by
system-wide decomposition. Therefore, system architecture is used to identify parts and
subassemblies to construct modular product architecture in this study [16].
Table 1 shows the previous research by various authors related to the key technolo-
gies and enablers of Industry 4.0 and smart manufacturing. This table also represents
the state of the art in Industry 4.0-related topics and current research. Various authors
have worked on different aspects of smart manufacturing, including improved quality of
production systems, inventory control, supply chains, and cost reduction [17–21]. Further
work includes modeling of flexible manufacturing systems, applying mass customiza-
tion strategies, effects of performance and variable production rates, and how to improve
production systems for Industry 4.0 [22–26].
Table 1. Review of previous research related to key technologies and enablers of Industry 4.0.
Topics (Key Technologies and

Research Conducted by Authors on Related Topics Authors
Enablers of Industry 4.0)
A B C D E F
(Walter Colombo et al., 2021, Uhlemann et al.,
2017, Hermann et al., 2016, Hehenberger and
A-Cyber physical systems (CPS) X
Eynard, 2017, Bagheri et al., 2015, Kagermann et al.,
2013, Bauernhansl et al., 2014) [27–33]
(Osterrieder et al., 2020, Wan et al., 2018,
B-Smart factory X X Wang et al., 2016, Radziwon et al., 2014,
Davis et al., 2012) [5,34–37]
(Lasi et al., 2014, Ning and Liu, 2015,
C-Internet of Service (IoS) X X
Buxmann et al., 2009) [38–40]
D-Internet of Things (IoT) X X (Wan et al., 2018, Witkowski, 2017) [35,41]
(Dikhanbayeva et al., 2020, Gorecky et al., 2016,
E- Design principles in Industry 4.0 X X
Hermann et al., 2016) [29,42,43]
F-Modular product architecture for
X Current Research
Industry 4.0 Environment
According to Ngjeqari [44], the 4th Industrial Revolution is an enabler of sustainable

development, but the convergence of digital transformation and sustainability remains
underdeveloped. Furthermore, previous research related to Industry 4.0 technologies and
approaches has not adequately addressed the issues of short product life cycles, volatile
user demands and interchangeable and sustainable modules. Therefore, to address the issue
of short product life cycles, companies can offer differentiated products by sharing modules
in the product families by applying product platforms. In addition, they can upgrade and
redesign products for the next generation. In the product platforms, the standard and
differentiated entities are balanced in the modular structure. Simply focusing on the Internet
of Things, automation of manufacturing processes, or the cost and efficiency of production
operations is no longer enough to compete in the global marketplace. Therefore, in this
study, a method is proposed applying a system architecture approach to develop modular
product architecture that supports identifying the product and manufacturing relationships
at the early design phase, customization, and sustainable flexible manufacturing system
for an Industry 4.0 environment. The study includes how the proposed method was used
in case studies of 3D printers and electric toothbrushes and validated it by applying it to
the development of product architecture.
The study also illustrates the hierarchical decomposition of the system in terms of
its functional and structural levels and the use of the Module Indication Matrix (MIM)
to identify the modules. The architecture of the products was developed based on the
analysis by assembling the nine modules and the various interfaces in the product structure.
In addition, product platforms were developed from the product architecture. Then, the
product-to-process relationships that support sustainable manufacturing planning were
illustrated, and a framework based on the proposed information and decision-making
method for Industry 4.0 solutions were represented. In addition, the study discusses the
significance of modular product architectures and managerial implications in the context
of the 4th industrial revolution.
2. Proposed Method
Modular product architecture not only improves sustainability performance from a
technological point of view but also improves its creative and social dimensions. Initially,
the modular product was used primarily for design engineering at the product level, but
with respect to time, the frameworks and methodologies of the modular product are used
for designing process and system levels. In this study, system architecting is used to define
systems, subsystems and their interfaces via hierarchical system decomposition. It is crucial
because the product’s general functions, significant subfunctions, and their relationships
are identified in the conceptual design phase [45,46].
Modularization approaches such as Modular Product Development (MPD), Design
Structure Matrix (DSM), and Modular Function Deployment (MFD) are widely used in
academia and industry. These methods have a variety of applications, from product design
to organizational domains [47,48]. However, they differ in terms of the aim of modular-
ization. These methods are also useful for system decomposition, module identification,
and modeling of interactions between elements, but they neither assist in modeling of
interfaces from function to form at various levels nor do they identify the product and
process relationships. Therefore, a method is required that supports modeling of interac-
tions from function to form at multiple hierarchical levels, identifies product and process
relationships, and supports customized products in a flexible manufacturing system for
Industry 4.0 environments as an enabler of sustainable development.
2.1. Method to Develop Product Architecture

This study investigates the Fused Deposition Modeling (FDM) type (direct extrusion)
3D printer system and electric toothbrush. First, both products were examined from product
manuals and then the data collected was used to analyze and synthesize the products.
These products were analyzed using quality function deployment, system decomposition
and module indication matrix. The analysis identifies the requirements and facilitates the
physical realization of the system in the form of modules and their interfaces. Then, a
synthesis of the systems was conducted to develop the product architecture and product
platforms [49,50]. Finally, the outcomes represent the manufacturing requirements and
framework model.
2.2. Steps in the Proposed Method

The proposed methodology is based on an iterative design with the following steps:
Step 1—Analysis
• Initially, quality function deployment (QFD), which is the key approach of the pro-
posed method, was employed and divided into four processes. First, the voice of the
customer (VOC), which consists of customer feedback, was recognized in order to
improve the product and process for a significant change. Second, the importance of
the customer requirements was identified, as this information is essential to properly
weight users’ needs in the QFD. Third, it was determined which product character-
istics have an impact on users’ needs. Fourth, mapping of the user needs to product
attributes was performed in the QFD.
• Then customer needs were converted into system-level specifications (i.e., abstract
descriptions for product modeling). In the system decomposition, the major functions
were broken down into subfunctions until no more functions could be obtained. The
system model is created by putting the functions into physical form. In system archi-
tecting, the product’s main functions, subfunctions and components were identified.
• Finally, in the analysis step, each technical solution identified from product decom-
position was analyzed against the module drivers to form potential modules. This
analysis was performed in a module interaction matrix (MIM). Technical solutions
identified in the system were essential in supporting the development of modules by
using module drivers [51]. In addition, the division of modules from the perspective
of sustainability and reliability was discussed.
Step 2—Synthesis
• During synthesis, the modules were assembled to build the product architecture. In the
product architecture, modules and their interfaces were developed. Product platforms
were then developed from the product architecture. Synthesis is based on the analysis
in the previous step; however, product architecture and platforms may change due to
market or technology requirements.
levels was developed to implement a sustainable flexible manufacturing system in
Industry 4.0.
• The flexibility and functionality of modular products make them more conducive to
sustainability. From the analysis and synthesis, companies can offer distinct products
by sharing modules across product families by using product platforms. This ap-
Sustainability 2023, 15, 910 proach enables them to upgrade and redesign products for future generations. This 5 of 29
will lower the cost of the product and increase production flexibility and sustainabil-
ity.
• Since it is an iterative process, any change or addition in modules due to new tech-
Step 3—Outcomes
nology or from the market will change the synthesis and analysis part, as shown in
• Figurebased
Finally, 1. on the analysis and synthesis, outcomes and implications, i.e., customiza-
tion,
Theinterface management,
overall approach and
comprises thesteps,
three flexible manufacturing
i.e., analysis, synthesissystems were as
and outcomes, built as
given
shownin Figure 1. The
in Figure 1.analysis represents
Furthermore, the QFD, system
a framework model decomposition and MIM.atSyn-
for decision-making different
thesis includes
levels product architecture
was developed and platform,
to implement while the
a sustainable product
flexible implications andsystem
manufacturing re- in
sults were displayed
Industry 4.0. in the outcomes.
Figure 1. Overall approach using analysis and system architecture to develop product architecture,
Figure 1. Overall approach using analysis and system architecture to develop product architecture,
platforms and a decision-making model.
platforms and a decision-making model.
• The flexibility and functionality of modular products make them more conducive to
sustainability. From the analysis and synthesis, companies can offer distinct products
by sharing modules across product families by using product platforms. This approach
enables them to upgrade and redesign products for future generations. This will lower
the cost of the product and increase production flexibility and sustainability.
• Since it is an iterative process, any change or addition in modules due to new tech-
nology or from the market will change the synthesis and analysis part, as shown in
Figure 1.
The overall approach comprises three steps, i.e., analysis, synthesis and outcomes,
as given in Figure 1. The analysis represents the QFD, system decomposition and MIM.
Synthesis includes product architecture and platform, while the product implications and
results were displayed in the outcomes.
3. Application of the Proposed Method

3.1. Case Study 1: 3D Printer
3D printing is one of the latest manufacturing technologies. Different types of methods
and technologies are employed for 3D printing. This case study is about Fused Deposition
Modeling (FDM), where the raw material (plastic filament) is melted and layers are added
to the 3D model. The main parts of FDM printer include an extruder, control panel,
threaded rods, frame, and print bed. The manufacturing of 3D printers has increased as
a result of rising demand. Currently, 3D printers are largely used for research; however,
in developed nations, they are also utilized for manufacturing purposes. As a result, 3D
printers are mostly utilized for three fundamental tasks, including research, manufacturing,
and education, or demonstration.
From the user’s perspective, requirements include the following:

• Functional performance (reliable, long-life time, less printing time, etc.);
• Physical requirements (e.g., size, weight, shape);
• Low price;
• Type of material that can be printed;
• Exchangeable parts (e.g., nozzle, rods, heaters, etc.);
• Easy maintenance;
• Ease of assembly and upgradation.
3.1.1. Analyze Requirements and Product Attributes by Applying Quality Function

Deployment Matrix (QFD)
Initially, the product properties are derived from the customer’s requirements. Once
the company-specific needs and market demands have been identified, the next step is
the use of the quality function deployment (QFD) matrix to analyze the customer require-
ments and the product attributes. This analysis helps to determine what essential product
properties can be used to fulfill the respective customer needs.
To know what customers, want in a 3D printer, it is necessary to first determine the
significance of each customer’s request. In this study, 3D printer data was collected through
a survey form. Based on the survey results, the customer requirements, along with the
weights, are enumerated in Table 2. There were a total of 11 customer demands for a 3D
printer, and 20 observations from various 3D printer users were acquired, as mentioned in
Table A1 in Appendix A.
Table 2. Importance of customer requirements for 3D printer.
S. No Customer Requirements Importance Values

1 Less time 5
2 Surface Finish 5
3 Low price 5
4 Easy maintenance 4
5 Safety 4
6 Easy to use 4
7 Type of materials 3
8 Low power usage 3
9 Connectivity 2
10 Maximum part size 2
11 Storage capacity 1
It is also important to find measurable product attributes that can be derived from
customer demands. Product attributes can be size, weight, shape, speed, range of material,
as well as assembly and modularization etc.
Relationship between Demands and Attributes:

For successful product design, it is important to transform the customer voice into
the essential technical requirement of the product. A careful analysis by participants from
the engineering, product development, manufacturing, and marketing departments is
often necessary to identify all related product attributes that affect customer demands.
Data about product attributes of 3D printers were collected from design and production
engineers. In this study, 3D printer data was collected through a survey form. The product
attributes for the 3D printers are modularization, motion control, level of control, power,
build area, weight, frame size, material, printing (parameters), and quality.
Next, the QFD was created, i.e., the relationship chart between customers’ demands
and product attributes, as shown in Table 3. The table is filled with three standard values:
9, 3, and 1, where 9 denotes a strong correlation, 3 is a medium correlation, and 1 a weak
correlation between needs and product attributes. In the QFD table, the points in a vertical
column represent that these demands are more important to consider with high weightage.
The large weights in the horizontal line, on the other hand, show that the product’s qualities
can generally meet 3D printer requirements. For instance, the surface finish of the 3D part
can be relevant to product properties, i.e., printing parameters, material and quality. A
need like printing (parameters) gets a higher score as it is associated with things like
surface finish and material type. A similar higher weighting is given to modularization,
which is associated with low cost, a variety of materials, and simple maintenance (due to
standardized modules).
3.1.2. Hierarchical Decomposition Using System Architecting to Identify Functions and

Select Technical Solutions
3.1.2. Hierarchical Decomposition Using System Architecting to Identify Functions and
Once the market requirements
Select Technical Solutionsand product attributes are identified, the next step
is to perform hierarchical
Once the product decomposition
market requirements usingattributes
and product systemarearchitecture
identified, theas defined
next step is
by Ulrich [52]. The decomposition
to perform hierarchical of the 3D
product printer isusing
decomposition represented in function-system-
system architecture as defined by
component domains, Ulrichas[52]. The decomposition
shown in Figure 2.ofInitially,
the 3D printer is represented
the functional in function-system-com-
decomposition reveals
ponent domains, as shown in Figure 2. Initially, the functional decomposition reveals that
that the main functions of a 3D Printer are: (a) to control, (b) to move, (c) to print (direct
the main functions of a 3D Printer are: (a) to control, (b) to move, (c) to print (direct extru-
extrusion), (d) to sion),
supply power,
(d) to supplyand (e)and
power, to support.
(e) to support.
3D printer
To Print 3D model
Function
To move To control To print To support
Main systems
Motion control User interface Power supply

system system Extruder system Support system
system
Components
Threaded Servo End Control Cold Transfor Print Reel

Belts Software Hot end Nozzle Heater Fan Switches Fan Frame
rods motors stops board end mer bed support
Figure 2.of
Figure 2. Decomposition Decomposition
3D printer of 3D Functions–Systems–Components
into printer into Functions–Systems–Components domain.The
domain. The main
main
functions are connected to the main systems. These systems are further decomposed into compo-
functions are connected
nents.to the main systems. These systems are further decomposed into components.
These functionsThese
are then linked
functions to core
are then systems
linked (e.g., motion
to core systems control
(e.g., motion system,
control system, user
user
interface system, extruder system, power supply system and support
interface system, extruder system, power supply system and support system). These core system). These core
systems provide information about the technical solutions in the form of modules. For
systems provide information about the technical solutions in the form of modules. For
instance, in the extruder system, threaded rods, hot end, cold end, belts and nozzle com-
instance, in the extruder
ponents aresystem, threaded
identified rods,
as technical hot end,
solutions. Thesecold end,solutions
technical belts and nozzle
are then com-
analyzed
ponents are identified
againstas
thetechnical solutions.
module drivers to form These
potentialtechnical
modules, assolutions
discussed are then
in the next analyzed
sections.
against the module drivers to form potential modules, as discussed in the next sections.
3.1.3. Module Identification and Their Reasons to form Modules Using Module Indica-
tion Matrix (MIM)
3.1.3. Module Identification and Their Reasons to form Modules Using Module Indication
Matrix (MIM) After decomposition, each technical solution derived from the product decomposi-
tion is assessed against the module drivers. As shown in Table 4, this analysis is carried
After decomposition, each interaction
out in a module technicalmatrix
solution derived
(MIM) from
where the the product
product technical decomposition
solutions are as-
is assessed against theagainst
sessed module drivers.
the module As shown
drivers inpossible
to generate Table 4, this analysis
modules. In the MIM,is module
carrieddriv-
out
ers are the
in a module interaction driving(MIM)
matrix forces the firm could
where generate modules.
the product technical There are 12 different
solutions module
are assessed
drivers, which together define the whole product lifecycle. The 12 module drivers are
against the module drivers to generate possible modules. In the MIM, module drivers are
technology evolution, planned design changes, different specifications, styling, ser-
the driving forcesvice/maintenance,
the firm could upgrading,
generate modules. There are
carry over, common 12process/organization,
unit, different module separate
drivers,
which together define
testing,the whole
supplier productand
availability, lifecycle.
recycling.The 12 module drivers are technology
evolution, planned design changes,
In the module different
interaction specifications,
matrix, each technical styling,
solution isservice/maintenance,
assessed with respective
upgrading, carrymodule
over, drivers
common on a unit,
scale (9,process/organization,
3, and 1) according to the importance
separate oftesting,
its reasons for be-
supplier
coming a module. According to this method, highly weighted and many and unique mod-
availability, and recycling.
ule drivers points toward the technical solution under consideration are likely to form a
ten
the necessary
engineering,
9, 3,engineering,
the and 1, where to identify
product
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product all related
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In the module interaction matrix, each technical solution is assessed with respective
module drivers on a scale (9, 3, and 1) according to the importance of its reasons for
becoming a module. According to this method, highly weighted and many and unique
module drivers points toward the technical solution under consideration are likely to
form a module. For example, the technical solution ‘stepper motor’ has higher scores in
carryover, common unit, and separate testability due to its strong relationship with them.
This is because the motor is carried from one generation to another and is a part of every
printer as a common unit. In addition, the motor can be separately tested or outsourced
to supplies. Due to its higher weight and unique module drivers, it might be a strong
candidate for a separate module named as motion module.
The technical solution ‘frame’ is scoring higher with planned design changes, process
organization, and different specifications due to its close association with them. This is
because frame design can be changed in different printers and is available in various
sizes, such as small and large ones. Further, its manufacturing process is the same for
various versions. Due to its higher weight and unique module drivers, it might be a strong
candidate for a separate module named as frame module. In this way rest of the modules
are identified, as shown in Figures 3 and 4. In the module indication matrix (MIM) of the
3D printer, the module drivers, such as common unit, process/organization, carryover,
and supplier availability, have big totals. This indicates a well-developed product (or
subassemblies) with a variety of options (Figure 3). A high carryover score indicates the
need for more technical solutions in future products. Customer demands are represented
by styling and different specification scores. Technology evolution and upgrading receive
lower scores.
Figure 3. The
Figure 3. The module
module driver
driver profile for 3D
profile for 3D printer.
printer.
Five modules, along with weightage

weightage and
and variants
variants in the 3D printer case, are shown
in Figure
Figure 4.4.These
Thesevariants include
variants a motion
include module,
a motion extruder,
module, printprint
extruder, bed,bed,
frame and user
frame and
interface.
user interface.
In the MIM (Table 4), seven of the most weighted technical solutions, along with the
print bed and power module, were chosen to develop nine modules in the 3D printer. This
Motion module
way, both hardware and software modules were identified in 30the 3D printer.
2
Software module 30
Filament and support 27
User interface module 25
2
Print bed module 10
1
Extruder module 21
2
Frame module 35
2
Power module 30
Control board module 21
Figure 3. The module driver profile for 3D printer.
Five modules, along with weightage and variants in the 3D printer case, are shown
in Figure 4. These variants include a motion module, extruder, print bed, frame and user
interface.
Motion module 30
2
Software module 30
Filament and support 27
User interface module 25
2
Print bed module 10
1
Extruder module 21
2
Frame module 35
2
Power module 30
Control board module 21
0 10 20 30 40
Weightage of each module
Variants
2 per. Mov. Avg. (Weightage of each module)
Figure 4. Nine of the modules with their weight and variants.

Figure 4. Nine of the modules with their weight and variants.
3.1.4.InDivision
the MIM of(Table
Modules4), seven of the
from the most weighted
Perspective technical solutions,
of Sustainability along with the
and Reliability
print bed and power module, were chosen to develop nine modules in the 3D printer. This
The recyclability, flexibility and functionality of modular products make them more
way, both hardware
conducive and software
to sustainability. modules
By creating were identified
products that can beinmodified
the 3D printer.
to fit new environ-
ments and meet changing needs, manufacturers offer customized products to markets.
3.1.4. Division of Modules from the Perspective of Sustainability and Reliability
Moreover, these products are more quickly built, reducing the amount of resource use.
The
In this recyclability,
study, the MIMflexibility
analysis and functionality
is used of modular
to reconstruct products make
the architecture them more
of a commercial
conducive
product intotoasustainability. By creating
modular architecture. Theproducts
sustainablethat can be modified
modular to fit new environ-
drivers, specifically interface
ments and meet
complexity, changing
upgrading, needs, manufacturers
recycling, and manufacturingoffer customized products
process similarity, aretoutilized
markets.to
Moreover, these products
drive sustainable modularare more quickly
design. Table 5 built,
showsreducing the amount
the 3D printer of resource
modules, use. In
the strongest
drivers for each module and sustainability in modules.
Table 5. Modules, their drivers and the reasons for sustainable modules.
S.No Modules Strongest Module Driver Sustainable Modules (Reasons for Sustainability)
Specific functions will carry over to different products,
1 Motion module Carry-over
reuse of these components
Flexibility and variety, manufacturing process
2 Software module Variance, process organization
similarity, economies of scale, and reduced costs
Separate testability, service Ease of assembly, high reliability with separate
3 Control board module
and maintenance testability, reuse, and recyclability
High-reliability part with separate testability provided
4 Power supply module Separate testability
by suppliers
Manufacturing process similarity, economies of scale,
Different specifications, and reduce costs,
5 Frame module
Process/Organization flexible manufacturing—group similar parts
operations together
Automation makes it possible to create an economy of
6 Extruder module Common unit
scale to reduce cost
7 Print bed module Planned design changes Design changes to reduce manufacturing costs
New functionality and flexibility to address market
8 User interface module Technology evolution
demands can be replaced in next-generation products.
9 Filament and support module Recycling Recyclability
3.1.5. Product Architecture: 3D Printer with Modules and Interface Design

Product architecture refers to how a product’s functional parts are organized into
physical units and how they interact [53]. The architecture of the 3D printer is developed
based on the analysis (using system architecting and module indication matrix) by assem-
bling the nine modules, as shown in Figure 5. The modular product structure assumes
that the design changes and a number of variants should not be spread within the whole
Sustainability 2023, 15, 910 system but be confined to just a few modules. In this product, variants are introduced12 of 26
only
in the nozzle, threaded rods, end stops, frame, build area, and user interface modules.
Filament and
support module
Filament
Frame module
Cover
Extruder Module
Cooling
Hot end
Fan
Power module
Cold End Nozzle

Transformer
Control board
& SW module
Fan Motion module Micro
controller
Stepper Threaded
motors rods
Software
Belts
User interface module

Print bed module
Switches
Bed
surface
Screen
Information
Physical
Energy
Module
Figure5.5.Product
Figure Productarchitecture
architectureofofthe
the3D
3Dprinter
printerwith
withmodules
modulesand
andinterface
interfacedesign.
design.
The
Theinterfaces
interfacesbetween
betweenthe
thecomponents
componentsareareshown
shownwith
witharrows.
arrows.Various
Variousinterfaces,
interfaces,
such
suchasasgeometrical
geometricalconnections,
connections,energy
energyflows
flowsand
andinformation
informationflows,
flows,can
canbe
beidentified
identified
between
betweenthethemodules.
modules.
3.1.6.
3.1.6.Product
ProductPlatforms
PlatformsandandProduct
ProductFamilies
Families
Modules and their interfaces in the product
Modules and their interfaces in the product cancan
be used to develop
be used product
to develop platforms
product [53].
platforms
From
[53].the 3D the
From printer analysisanalysis
3D printer and synthesis in the preceding
and synthesis section, it section,
in the preceding is feasible to feasible
it is constructto
product
construct product platforms and families. Companies can offer distinct productsmodules
platforms and families. Companies can offer distinct products by sharing by shar-
ing modules across product families using product platforms. This will lower the cost of
the product and increase production flexibility and sustainability. Companies can also
upgrade and redesign products for future generations.
In the 3D printer example, nine software and hardware modules are identified in the
module identification matrix. With software modularity, it is possible to move the soft-
across product families using product platforms. This will lower the cost of the product
and increase production flexibility and sustainability. Companies can also upgrade and
redesign products for future generations.
In the 3D printer example, nine software and hardware modules are identified in the
module identification matrix. With software modularity, it is possible to move the software
solution from one hardware to another and enable hardware portability and scalability.
Sustainability 2023, 15, 910 One platform is developed that comprises common entities used in all four variants of 13 of
the26
3D printer, as shown in Figure 6.
Common modules Product families

Product platforms
standard entities (based on variants)
Filament and
Research use
support Module
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Smaller bed area
Multi nozzles
User interface
Module
Industrial setup
Print bed Module Efficient control board
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Extruder module
Platform 1
Personal use
Small frame
Frame module Small power supply
Simple user interface
Power module
Educational purpose
Small frame
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module Single nozzle
Motion module
Software module
Figure6.6.Product
Figure Productplatform
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This platform is
is also
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product families
families such
such as
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3D printers
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for research,
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and manufacturing,
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derivative products
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be created
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3.2.
3.2. Case
Case Study
Study 2:
2: Electric
Electric Toothbrush
Toothbrush
To
To develop modular architecture,
develop modular architecture, Electric
Electric Brush
Brush is
is used
used as
as an
an illustrative
illustrative example.
example.
Electric
Electric toothbrushes, a new form of a battery-powered toothbrush with
toothbrushes, a new form of a battery-powered toothbrush with anan oscillating
oscillating
brush
brushhead,
head,are
arebecoming
becomingmoremorepopular.
popular.The
Themain
mainparts
partsof
ofthe
the device
device are
are the
the battery
battery pack,
pack,
electrical
electricalmotor,
motor,drive
driveshaft,
shaft,brush
brushhead,
head,control
controlcard
cardand
andcharging
chargingunit.
unit.
A global “small appliance” manufacturer has decided to introduce a new global
toothbrush platform, focusing on three key end-user segments: Young, Family and Trav-
eler. According to a market survey, the top customer demands and functionality for each
segment are as follows:
• Functional performance (high impact resistance, long lifetime, long battery life, quick
A global “small appliance” manufacturer has decided to introduce a new global

toothbrush platform, focusing on three key end-user segments: Young, Family and Traveler.
According to a market survey, the top customer demands and functionality for each segment
are as follows:
• Functional performance (high impact resistance, long lifetime, long battery life, quick
charging, variable speed, timer function, etc.);
• Physical requirements (e.g., size, weight, and shape);
• Low price;
• Exchangeable cover;
• Easy maintenance, ease of assembly, and upgradation.
It is also important to find product attributes that are measurable and derive from
customer demands. Product attributes can be size, weight, shape, speed, range of material,
as well as assembly and modularization etc.
3.2.1. Analyze Requirements and Product Attributes by Applying Quality Function

Deployment Matrix (QFD)
Initially, the product attributes are derived from the customer’s requirements. Once
the company-specific needs and market demands have been identified, the next step is the
use of the quality function deployment (QFD) matrix to analyze the customer requirements
and the product attributes. This analysis helps determine what essential product properties
can be used to fulfill the respective customer needs.
To know what customers want in an electric toothbrush, it is necessary to first de-
termine the significance of each customer’s request. Therefore, electric toothbrush data
was collected through a survey form. The customer requirements and the weights were
identified based on the survey results. There were a total of 12 customer demands for
an electric toothbrush, and 20 observations from various electric toothbrush users were
acquired, as mentioned in Table A2 in Appendix A. Referring to Table 6, requirements like
degree of variation in use (variety) have a higher score and is an indication of future trends.
Similarly, another higher weight-age is for modularization, which is related to flexibility in
use, upgradation and easy maintenance (due to standardized modules). Furthermore, the
material is relevant to long life and reliability concerns.
3.2.2. Hierarchical Decomposition Using System Architecture to Identify Functions and

Select Technical Solutions
Once the market requirements and product attributes are identified, in the next step,
the hierarchical product decomposition is performed using system architecting tasks to
develop product architectures in the way defined by Ulrich [54]. The toothbrush is de-
composed into function, system, and component domains, as shown in Figure 7. The
major functions of an Electric Brush are (a) to control, (b) to rotate, (c) to give power, and
(d) to support, according to the functional decomposition.
Following that, these functions are linked to core systems (e.g., motion control system,
power conversion system, power supply system and support system). These basic systems
provide information about technical solutions in the form of modules. For example, techni-
cal solutions in the control system include motor control, circuit board, LED, timer, and
oscillator components. These technical solutions are then analyzed against the module
drivers to build possible modules, as described in the following sections.
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the customer
features
customerare demand
essential
demand andand
andmay then
thenbe added
changed
added vertically.
to meet
vertically. Arrows
specific
Arrows indicate
customer
indicate possible
requirements.
possible future
future Thetrends for
relationships
trends cus-
cus-
Shape
Power
Product Attributes(due to standardized modules).
Material
Trend
Printing
tion,surface
which is associated with low cost, a variety of materials, and simple to maintenance
Control
Total
(Filament)
Quality Quality
Size
Modularization
like finish and material
Motion
type. A similar a higher weighting isisassociated
given modulariza-
Control
Weight Weight
Weight Weight
quality.
tomer
are
tomer A from
needs.
ranked
needs. need 9like printing
(strong), (parameters)
3 (medium), and 1gets(weak). higher
The grades score are as itmultiplied by with
the weightthings of
Power Power
(Parameters)
Frame
Trend
of Level
Product Attributes(due to standardized modules).
Sum
of Control
(Size)
(Filament)
Less time for printing the customer 5 demand and then 9 added 9 vertically. Arrows indicate possible future3 trends for 21
cus-
Modularization
like surface finish and material type. A similar higher weighting is given to modulariza-
Control
Product Attributes Table 3. Quality function deployment matrix for 3D printer. This matrix illustrates which product
Area
(Parameters)
Product Attributes
Product Attributes
(due
tomer
tion, to standardized
needs.
which is associated andmodules).with low cost, a variety ofcustomer
materials, and simple maintenance
Control
(Size)
features
Table 3.5are 5 essential may
1 be changed to meet for specific requirements. 9The relationships
(Filament)
Modularization
Control
Surface finish of the part 3illustrates 9 product 21
Material
Printing
Easy to use Quality function deployment 1 matrix 3D printer. This matrix which 9 11
Area
Motion
Less time for printing (due
are to
ranked 5
standardized from 9 (strong),modules).
3 9
(medium), 9 and 1 (weak). The grades are multiplied 3 by the weight 21 of
Frame
Trend
(Parameters)
Control
(Size)
Build
Level
Modularization
Material
Control
Product Attributes
Printing
Table 3. Quality function 9 deployment addedmatrix 3for 3D printer. 3 This matrix illustrates trends
which product
Sum
Low price 5 demand 3 possible for18
Quality
the customer and then vertically. Arrows indicate 33 future cus-
Area
Motion
Weight
Weight
(Filament)
Surface
High impact
Customer finish
resistance of the part
Requirements are ranked 5 5 from 9 (strong), 3 (medium), and 1 (weak). The grades are multiplied 9 by the9 weight 21 of 3
Power
Frame
Trend
Build
ofLevel
(Size)
Material
tomer needs.
Printing
Table 3. Quality function 9 deployment3 added3matrix for 3D printer. This matrix illustrates which product
Sum
of
Easy maintenance 4 demand 3 possible 18
Quality
of Control
the customer and then vertically. Arrows indicate future trends for cus-
Motion
Weight
Weight
Area
Modularization
Control
Low
Less price
Customer Requirements are ranked 55 from 9 (strong),
and9may 3 (medium), 9 and 31 (weak). The 3grades3are multiplied by the weight 21 of
18
Power
Frame
Trend
Long lifetime time for printing features 5are essential be9 changed to meet specific customer requirements.9 3The relationships 9
Build
Level
tomer needs.
Material
Sum SumSum
Printing
(Parameters)
Safety 4 1 3 4cus-
Quality
the customer demand and then added vertically. Arrows indicate possible future trends for
(Size)
Motion
Product Attributes
Weight
Weight
Customer
Easy Requirements
maintenance are ranked 5 45 from 9 (strong), 3 (medium),
9 1 39 3 39 and 1 (weak). The grades 3are multiplied by the weight 118 of
Power
Frame
Less time for printing 3 21
(Filament)
TrendTrend
Low price
Surface finish of the part 33 9 9 1 1 8
Area
BuildBuild
Level
Easy to use Product Attributes tomer needs.
4 demand and then added vertically. 9 3 possible future trends for12
(Parameters)
the customer Arrows indicate cus-
Material
Printing
Customer
Safety Requirements 4 45 1 9 3 39 4
Control
Customer
Less time Requirements
for printing 9 9 3 21
(Filament)
Quality Quality
Variable speed
Surface finish of the part 9 3 3 12
Modularization
Motion
Control
Weight Weight
Weight Weight
Low price tomer needs. 35 99 3 3 18
Power Power
(Parameters)
Frame
Type of materials for printing 9 9 27
of Level
Easy to use Product Attributes 45 9 3 12
of Control
Less time for printing
printing 99 99 33 21
(Size)
(Filament)
Indication
Less when charged 4 5 3 3
Easytime
Surface for
finish of the part 3 9 9 21
Modularization
Control
Low price
maintenance 5 9 3 3 3 18
Customer Requirements 34 3 3
(Parameters)
Area
Low power usage
Product Attributes 9 9 Control
Type of materials forpart
printing 4 3 99 9 9 327
(Size)
(Filament)
Surface finish of
of the
the part 5554 33 99 99 21
Modularization
Control
Surface finish 21
Material
Printing
Low
Long battery
Safety
Easy price
life
maintenance 93 93 3
1 3 3 3 18
94
9 12
Area
Motion
Less time
Connectivity for printing 52 3 3 3 21
Frame
Trend
Control
(Size)
Build
Low power usage 3 9 9
Level
Modularization
Control
Material
Printing
Low price
to usePart size 5254 99 339 33 33 18
12
Sum
Safety
Low
Easy price
18
Quality
Area
Motion
Maximum 9
Weight
Weight
Quick Surface finish
battery charging
Customer of the part
Requirements 3 5 3 9 921 1 3 13
Power
Frame
Trend
Connectivity 2 3 3 3 94
(Size)
Build
Level
Material
Printing
to
of use 9 3 12
Sum
of
Safety
Easy maintenance
Typemaintenance
Easy materials for printing 4143 99 33 33 1 33 9 9 3 18
27
18
Quality
Area
Motion
Weight
Weight
Storage
Low
Customerpricecapacity
Requirements 3 5
9
9 33 3 33
9 18
18
Power
Frame
Trend
Less
Exchangeable
Maximum time
coverfor printing
Part size 25 9 9 9 3 21
9 1 7 Build
Level
Material
Printing
Easy to
of use 9 3 12
Sum
of
Safety
Type
Safety materials
usage for printing 443 9 11 9 9 33 44
27
Quality
Low power 9 9
Motion
Weight
Weight
Sum
Customer Requirements 117 57 57 55 6 15 27 66 93 48
Power
Easy maintenance 3 4 9 39 39 93 18
Frame
Trend
Less
Easy upgradation
Surface time for
finish printing
of the part 1454 3 3
9 99 21 9
Build
Storage capacity 99 18
Level
Easy to use 99 33 12
Sum
Easy
Typeto ofuse
Connectivity
Low powermaterials
usage for printing 32 3 9
3 9
3 9 12
27
9
Customer
Timer Safety
Less
function
Surface
Sum time Requirements
for
finish printing
of the part 2 45 117 579 9
57 1
55 6 15 327 663 933
9 39
48 4
21 3
Low
Type
Maximum price
of materials
Connectivity
Type
Low of
powermaterials
Part
usage for printing
size
for printing 3532 99
9 3 3 3 3 99
3 99
3 9 18
27
27
9
Easy
Less
Easy maintenance
Surface to use
time for printing
finish of the part 2 45 9 9 9 3 93 3 3
9 9 12
21 3 12
Low price
Easy power
Maximum
Connectivity
Low
Storage
Low power Part
usage
capacity
usagesize 33214 9 3 3 3 9
3 3 99 99
18
Total Type
Surface
Low of materials
price forpart
finish of the printing 355 9 10 20 39 36 3 60 9375 99 12 9 4427
21 15 14 45 50
Safety
Easy
Sum maintenance
Maximum
Connectivity
Storage
Connectivity Part size
capacity 2421 9
9
117 573 3
57 551 33
6 15 273 669
33 33
93 3
9
48 94
18
9
18
Low
Low power
price usage 354 9 3 3 3 93 94
18
Sum to
Safety
Easy
Maximum
Maximum
Storage use
maintenance
Part size
Part
capacity size 221 9
117 573 3
57 559
1 6 15 27 99
66 93 9
48 12
99
18
Connectivity
Safety to use 2 9
1 3 3 3 3 3 94
12
Easy
Type
Storage maintenance
of
Sum capacity
Storage materials
capacity for printing 11 4
3 9
99
117 573 3
57 55 6 15 273 669 939 99
48 18
27
18
18
Maximum
Easy to Part size 2 9 9
Safety
Type
Low power
Sum
Sum of use
materials
usage for printing 43 9
117
117 57
57 57
57 55
55
9
1
66 15
15
3 27
27 66
669 93
939 3
9
48
48
12
4
27
9
Storage
Easy
Type to
of capacity
use
materials for printing 1 4
3 99 9 3 9 9 9 18
12
27
Connectivity
Low power usage 2 3 3 3 9 9
Sum
Type
Maximum of materials
Part for
size printing 3 117
9 57 57 55 6 15 27 669 939 48 27
Connectivity
Low power usage 2 3 3 3 9 9
Maximum
Connectivity
Low
Storage power Part
usage
capacity size 231 9 3 9
3 3 9 9
18
Maximum
Storage
Sum Part size
Connectivity
capacity 21 9
117 57 57 55 3
6 15 27 9
3
66 3
93 9
48 9
18
Following that, these functions are linked to core systems (e.g., motion control sys-
tem, power conversion system, power supply system and support system). These basic
systems provide information about technical solutions in the form of modules. For exam-
ple, technical solutions in the control system include motor control, circuit board, LED,
Sustainability 2023, 15, 910 timer, and oscillator components. These technical solutions are then analyzed against
16 of 29the
module drivers to build possible modules, as described in the following sections.
Electric tooth brush
To clean teeth
Function
To Control To rotate To supply power To support
Main systems
Motion control system To convert power Power supply system Support system
Components
Circuit Motor Axle Electrical Chargible Transform Brush

LED Oscillator Timer Gearbox Charger Chassis Cover Base
board control assembly motor battery er head
Figure
Figure7.7.Decomposition
Decompositionof of
electric toothbrush
electric into
toothbrush Functions–Systems–Components
into Functions–Systems–Componentsdomain.
domain.The
main functions are connected to the main systems. These systems are further decomposed
The main functions are connected to the main systems. These systems are further decomposedinto com-
ponents.
into components.
3.2.3.Module
3.2.3. Module Identification
Identification and
andTheir
TheirReasons
ReasonstotoForm
Form Modules
Modules Using Module
Using Module Indication
Indica-
Matrix (MIM)
tion Matrix (MIM)
Each technical solution derived from the product decomposition is assessed against
Each technical solution derived from the product decomposition is assessed against
the module drivers. As indicated in Table 7, this analysis is carried out in a module
the module drivers. As indicated in Table 7, this analysis is carried out in a module inter-
interaction matrix (MIM) where the product technical solutions are assessed to generate
action matrix
possible (MIM)
modules. where
In the MIM,theeach
product technical
technical solutions
solution is rated onarea assessed
scale of (9,to3,generate
and 1) and pos-
sible
assessed with respective module drivers for the importance of its reasons for becoming aand
modules. In the MIM, each technical solution is rated on a scale of (9, 3, and 1)
assessed
module.with respective
According module
to this drivers
approach, forweighted,
highly the importance
many andof its reasons
unique for becoming
module drivers a
module.
indicate According to thissolution
that the technical approach, highly
under weighted,ismany
consideration likelyand unique module
to constitute a module.drivers
indicateIn that the technical
the module solution
indication under
matrix consideration
(MIM) is likely
of an electric to constitute
toothbrush, there aaremodule.
large
totals for the module drivers, such as common unit, carryover, various specifications,
and separate testability. This indicates a mature product with variants availability and
acceptable quality as a result of separate testability. A high carryover score indicates more
technical solutions for next-generation products. Score by different specifications and
styling represents external factors related to the user’s requirements. Lower scores for
recycling and service/maintenance indicate the need for after-sales support. However,
there are no scores for product upgrades and planned design changes, as demonstrated in
Figure 8.
Table 7. In the module indication matrix, each technical solution from the system architectu
is assessed against the module drivers. Where, = 9 (strong relation), = 3 (medium relation
Sustainability
Sustainability
2023, 15, 2023,
910 15, 910 Sustainability
Sustainability
2023, 15, 2023,
910 15, 910 (weak relation). 16 of 26 16 of 26 16 of 26 16
Sustainability 2023,Sustainability
15, 910 Sustainability
2023, 15, 2023,
910 Sustainability
15, 910 2023, 15, 910 Sustainability 2023,Sustainability
2023, 15, 2023,
910 15, 910 16 of 26 16 of 26 16 of 26 16 of 26
15, 910 2023, 15, 910 Technical Solutions 16 of 26 16 of 26
On/off Switch Electrical Motor

Sustainability 2023, 15, 910
Axle Assembly
Motor Control
On/off Switch
Motor Circuit Board
Table 7. In the module indicationTable matrix, each
7.Table
In the7. technical
module
In the module solution
indication from
indication
matrix,
Table the7. system
each
matrix,
Table
In the 7.architecture
technical
each
module technical
In the solution
module
indicationphase
solution
from is
the
indication assessed
matrix,from
system theagainst
each
matrix, each the
architecture
system
technical module
architecture
technicalphasesolution
solution drivers.
fromphasethefrom Where,
system = 9 (strong
the architecture
system architecture
phase ph
LED Control Transformer
Brush Head
Chargeable
Table 7. In the module
Table 7.indication
Table
In the 7.
module
Inmatrix,
the module
indication
Table
each 7.
technical
indication
In matrix,
the module
solution
each
matrix, technical
indication
Table
from
each 7.
the
technical
solution
In matrix,
system
the module
Table
solution
from
each
architecture
7.
the
technical
indication
Table
In
from
system
the 7.
phase
the
module
solution
In architecture
matrix,
system
the module
indication
from
each
architecture
phase
the
technical
indication
matrix,
system phasesolution
each
architecture
matrix, technical
from
each phase
the
technical
solution
system
andsolution
from
=archite th
Motor Control End Cover

relation), = 3 (medium relation) and = 1 (weak
is assessed relation).
is assessed
against the
against module the module
drivers. drivers.
Where, Where,
= 9 (strong = 9module
Motor Oscillator
against the
against relation),
(strong
the modulerelation),
= 3 (medium
drivers. = 3 (medium
drivers.
Where, relation)
Where,
= 9 (strong relation)
= and = 1 and
9 relation),
(strong == 31 (medium
relation), = 3 (medium relation) relation) 1 and
On/off Switch Gear Box

Table 7. In the module
Table 7.indication
Inassessed
the modulematrix, indication
each technical
matrix, solution
each technical
from the solution
system from
architecture
the system phase architecture phase
Charger
is assessed againstis assessed
the module
is against drivers.
the
against module
is
Where,
assessed
the module
drivers.
= 9 against
(strong
drivers.
Where,the
relation),
module
is
Where,
= assessed
9 (strong
= 3
drivers.
= (medium
9 against
relation),
(strongis
Where,
assessed
the
relation)
relation),
= module
3is
= (medium
assessed
9 against
(strong
and
= 3
drivers.
=
(medium
1the
against
relation)
relation),
module
Where,the
relation)
and
= module
3
drivers.
= =(medium
9 1(strong
and drivers.
Where,
= 1relation)
relation),
Where,
= 9 (strong
and
= 3= =
(medium
9 1relation),
(strong relat
relat
= 3
Board Chassis
Battery
(weak relation).
(weak relation).
Cover
Sustainability 2023,Drivers
is assessed
(weak against
relation).
is assessed
(weaktherelation).
2023,Sustainability
15,
module
(weak against drivers.
2023,relation).
910 Sustainability
the module
15, 2023,
910 15,
Where,
(weak drivers.
= 9 (strong
910 relation).
Where, relation),
= 9 (strong
(weak =Sustainability
Sustainability
3 (medium
relation). relation),
2023, 15, (weak relation)
2023,
=relation).
315,(medium
(weak
910 Sustainability
and Table= 2023,
relation).
910Sustainability
1relation)
16 7.15,
In2023,
of the
26
910
and =1
module
15, 910 indication 16 of matrix,26 each16technical
of 26 16
Motor Base
LED
Module
Battery
(weak relation).(weak relation). Module Drivers is assessed against the module drivers. Where, = 9 (stro
Technical Technical
Solutions
SustainabilitySolutions
2023, 15, 910 Sustainability 2023, 15, 910
Motor
Motor
Motor
Motor
Technical Solutions Technical Technical
Solutions Solutions
Technical Solutions Technical
Carryover Solutions Technical Technical
Solutions Solutions (weak relation).
Axle Assembly
Assembly
Assembly
Assembly
Assembly
Motor Control
Sustainability 2023, 15, 910 Sustainability 2023, 15, 910 Sustainability 2023,Sustainability 15, 910 2023, 15, 910 16 of 26
Control
Control
Switch
Timer Switch
Switch
Motor
Motor
Box Motor
Box Motor
Motor
Board
Technical Solutions
Technical Solutions
Board
Board
Cover Board
Assembly
Assembly
Assembly
Assembly
Assembly
Assembly
EndAssembly
Transformer
2023, 15, 2023,
910 Sustainability
15, 910 2023, 15, 910 Sustainability 2023, Sustainability
2023, 15, 2023,
910 15, 910 16 of 26 16 of 26 16 of 26 16 of 26
Transformer
Transformer
Transformer
Transformer
Control
Control
Control
Control
Control
Head
Switch
Switch
Switch
Switch
Switch
Switch
Technical push
Motor
Motor
Head
Brush Head
Head
Head
Chargeable
Chargeable
Chargeable
Chargeable
Chargeable
Board
Board
Board
CoverBoard
Board
Board
Board
Assembly
Assembly
End Cover
Table 7. In the module indication
Table 7. Inmatrix,
Design the module
Table
each 7. technical
indication
Table
In the7. module
solution
Inmatrix,
the module
indication
from
each the
technical
indication
Technical matrix,
system solution
each
architecture
matrix,
Solutions technical
Table
from
each 7. phase
the
technical
Table
solution
Insystem
the7. module
solution
In
from
architecture
the the
module
indication
Table
from
system 7.
phase
the
Table
indication
Inarchitecture
matrix,
system
the7.module
Ineach
architecture
matrix,
the module
phase
technical
indicatio
eachin ph
te
Cover
Cover
Transformer
Transformer
Switch Transformer
Transformer
Transformer
End Cover
Transformer
End Cover
Transformer
Control
Control
Switch
Switch
Oscillator
Oscillator
Oscillator
Oscillator
Head
Head
Head
TotalHead
Head
Motor Head
Axle Assembly Oscillator
Box
Electrical
Board
Chargeable
Board
Chargeable
Chargeable
Chargeable
Chargeable
Chargeable
Assembly Chargeable
Electrical
Electrical
Electrical
Electrical
Box
Box
Box
Base Box
Planned the design
Motor
Sustainability 2023, 15, 910 16 ofassessed
26
Charger
Transformer
Transformer
Cover
Cover
Cover
Cover
Cover
is assessed against the module is assessed drivers.
againstis
Where,
assessedmodule
is= assessed
9 against
(strongdrivers.
the
against
relation),
module
Where,the= module
3drivers.
=(medium
9 (strong drivers.
Where,relation)
relation),
isWhere,
= assessed
9 (strong
and
= 3is==(medium
assessed
91against
relation),
(strong the against
relation)
relation),
= module
3is(medium
assessed
the
and
=ismodule
3drivers.
=(medium
1against
relation)
drivers.
Where,
against
the
relation)
and module
Where,
==9the 1(stro
andmd
Chassis
Charger
Charger
Charger
Charger
Assembly
Head
Head
Oscillator
Oscillator
Circuit Board Oscillator
Oscillator
Oscillator
Oscillator
Oscillator
Chassis
Chassis
Chassis
Chassis
Circuit
Chargeable
Chargeable
Electrical
Electrical
Electrical
Electrical
Electrical
Gear Electrical
Switch Electrical
Battery
Battery
Box
Box
Box
Box
Battery
Battery
Box
Table 7. In the module indication matrix, Table
each 7. technical
In the module solution indication
from the matrix system
Circuit
Circuit
Circuit
Circuit
On/off
On/off
On/off
Cover
Cover
Brush
Motor
Motor
Motor
Cover
Timer
Board
changes
Timer
Timer
Timer
Charger
Charger
Charger
LED Board Charger
Charger
Charger
Axle Assembly Charger

Cover
Cover
Brush
Brush
Brush
Oscillator
Oscillator
Chassis
Chassis
Chassis
CoverAssembly Chassis
Chassis
Chassis
CoverAssembly Chassis
Gear
(weak relation). (weak 910 relation). (weak 7. relation).
(weak
In the relation). (weak 7. relation).
(weak the relation). (weak 16relation).
(weak relation).
Total
Transformer
Total
Total
Electrical
Electrical
Box
Box
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Gear
Gear
Gear
Gear
Base
15, 910 Table moduleSustainability
indication
Table 7. Inmatrix,
the module
15,each technical
indication
Table solution
In2023,
matrix, module
Table
from
each 7.
the
technical
indication
Insystem
the module
solution
architecture
matrix, indication
offrom
each phase
the
technical
matrix
system
On/off
On/off
On/off
On/off
On/off
On/off
Axle
Sustainability
Sustainability
2023,Sustainability
15, 2023,
910 Sustainability
15, 2023,
910 15, 2023, 2023, 910 Sustainability 15, 910 of 26the 16 26 16 of(mediu
26 16
Axle
Base
Axle
Axle
Base
Base
LED
LED
LED
LED
Motor
Motor
Motor
Motor
Chargeable
is assessed against the module drivers. is
Where,
assessed = 9 against
(strong relation),
module = 3
drivers.
Timer
Timer
Timer
Timer
Charger
Charger
End
Cover
Cover
Cover
Motor Control Cover
Cover
Cover
Control Cover
Brush
Brush
Brush
Brush
Brush
CoverBrush
Chassis
Chassis
Total
Total
Total
Total
Battery
Battery
ModuleModule
Drivers Drivers
Table 7. In the module Module
Table Module
Drivers
7.indication
Table
In the7. Drivers
module
Inmatrix,
the module Different
indication
Table
each 7.
technical
indication
Inmatrix,
the module
solution
each
matrix, technical
indication
Table
from
each
the7.the
technical
solution
Inmatrix,
system
the module
Table
solution
from
each
architecture
7.
the
technical
indication
Table
In
from
system
the
the7. phase
the
module
solution
=Inarchitecture
matrix,
system
9the module
indication
from
each
architecture
phase
the
technical
indication
matrix,
system
the=phase
3solution
each
architecture
matrix, technical
from
each phase
the
technical
solution
system solution
=from
archite th
Circuit
Circuit
Gear
Gear
Gear
Gear
Gear
Gear
Gear
On/off
On/off
Axle
Axle
Axle
Axle
Base
Axle
Base
Base
Axle
Axle
Base
Base
Base
Board Base
Oscillator
LED
LED
LED
LED
LED
Motor
Brush Head Motor

Timer
Timer
is assessed against module
is assessed drivers.
against Where, module
is assessed
(strongdrivers.against
relation),
is
Where,
assessed module
=(medium
9 against
(strong drivers. the
relation)
relation),
module
Where, and
= 3drivers.
=(mediu
91(stro
End
End
End
End
End
Cover
Chargeable Cover
Electrical
Brush
Brush
Box
Technical Solutions Module DriversModuleModule (weak relation). (weak relation).
Total
Total
Drivers Drivers Module Drivers Module Drivers Module Module
Drivers Drivers
Gear
Gear
Charger
Axle
Axle
Base
Board Board Base

LED
LED
AssemblyChassis
Technical is assessed
Solutions againstis
Technicalassessed
the module
is assessed
Solutionsagainst drivers.
Variance
Technical the
against module
is
Where,
Technical
Solutions specification
assessed
the module
drivers.
= 9
Solutionsagainst
(strong
drivers.
Where,the
relation),
module
is
Where,
= assessed
9 (strong
= 3
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quality as a result of separate testability. A high carryover score indicates more technical
solutions for next-generation products. Score by different specifications and styling rep-
resents external factors related to the user’s requirements. Lower scores for recycling and
Sustainability 2023, 15, 910 service/maintenance indicate the need for after-sales support. However, there are 18 ofno
29
scores for product upgrades and planned design changes, as demonstrated in Figure 8.
Figure8.8.The
Figure Themodule
moduledriver
driverprofile
profilefor
forthe
theElectric
ElectricTooth
ToothBrush.
Brush.
Figure
Figure99depicts
depictsthe
theweighting
weightingof ofeach
eachmodule
moduleas aswell
wellasasthe
thevariants.
variants.In
Inthe
theMIM
MIM
matrix,
matrix,four
fourmodules
modules with variants
with are are
variants identified to address
identified the three
to address the market sectors.sectors.
three market These
variants are in the
These variants arecharger, battery, battery,
in the charger, brush head and
brush PCBand
head modules.
PCB modules.
Chassis module 18
Styling module 12
Transmission module 21
Switch module 19
PCB module 27
3
Brush head module 30
2
Charger module 30
2
Battery module 34
2
Electric motor module 28
0 10 20 30 40
Weightage of each module

Variants
2 per. Mov. Avg. (Weightage of each module)
Figure9.9.Each
Figure Eachmodule’s
module’sweight
weightand
andvariants
variantsare
areidentified
identifiedininthe
themodule
moduleindication
indicationmatrix.
matrix.
In
Inthe
theMIM,
MIM,seven
sevenofofthe
themost
mostweighted
weightedtechnical
technicalsolutions,
solutions,along
alongwith
withchassis
chassisand
and
styling,
styling,were
werechosen
chosentotodevelop
developnine
ninemodules
modulesfor
forthe
theelectric
electrictoothbrush.
toothbrush.
3.2.4.
3.2.4.Product
ProductArchitecture:
Architecture:Electric
ElectricToothbrush
Toothbrushwith withModules
Modulesand andInterface
InterfaceDesign
Design
The
The architecture of the electric toothbrush is developed based on the analysis(using
architecture of the electric toothbrush is developed based on the analysis (using
system
systemarchitecting
architectingand
andmodule
moduleindication
indicationmatrix)
matrix)by byassembling
assemblingthe thenine
ninemodules.
modules.TheThe
modular product structure assumes that the design changes and a
modular product structure assumes that the design changes and a number of variantsnumber of variants
should
shouldnotnotbebespread
spreadwithin
withinthethe
whole
whole system butbut
system be confined to just
be confined to ajust
fewa modules. In this
few modules. In
product, variants are introduced only in the battery, charger, brush head and
this product, variants are introduced only in the battery, charger, brush head and PCB PCB modules.
The interfaces between the components are shown in Figure 10 with arrows. Various
modules.
interfaces can be identified
The interfaces between between the modules,
the components including:
are shown in Figure 10 with arrows. Various
interfaces can be identified between the modules, including:
• Physical or geometrical connections.
• Energy flows (e.g., mechanical rotary, electrical, thermal, etc.).
• Information flows (e.g., sensor signals, actuator commands, and control commands)
The architecture of the electric toothbrush is developed based on the analysis (using
system architecting and module indication matrix) by assembling the nine modules. The
modular product structure assumes that the design changes and a number of variants
should not be spread within the whole system but be confined to just a few modules. In
Sustainability 2023, 15, 910 this product, variants are introduced only in the battery, charger, brush head and PCB19 of 29
modules.
The interfaces between the components are shown in Figure 10 with arrows. Various
interfaces can be identified between the modules, including:
• • Physical
Physicalororgeometrical
geometrical connections.
connections.
• • Energy
Energy flows(e.g.,
flows (e.g.,mechanical rotary,electrical,
mechanical rotary, electrical, thermal,
thermal, etc.).
etc.).
• • Information
Information flows (e.g., sensor signals, actuator commands, andand
flows (e.g., sensor signals, actuator commands, control
control commands)
commands)
PCB Module Chassis module
Main Control board Motor Battery Charger

Transmission Motor control
Brush head circuit module module
module module On&Off
contact
CPU
Switch Styling
module module
Battery
LED circuit
Information
Physical
Sustainability 2023, 15, 910 Signal
18 of 26
Energy
Module
Figure 10.
Figure 10.Product
Productarchitecture of theofelectric
architecture toothbrush
the electric with modules
toothbrush withand interface
modules design.
and interface design.
Designers
Designers and
andengineers have have
engineers the crucial role of finding,
the crucial role of creating,
finding,and optimizing
creating, and optimizing
modules and their interactions in the early stages of systems design by examining the
modules and their interactions in the early stages of systems design by examining the
system architecture of existing products.
system architecture of existing products.
3.2.5. Product Platforms and Product Families
3.2.5.From
Product Platforms and Product Families
the toothbrush analysis and synthesis in the preceding section, it is feasible to
From
construct the toothbrush
product platforms and analysis
families.and synthesis
Companies can in thedistinct
offer preceding section,
products it is feasible to
by shar-
ing modules
construct across product
product families
platforms and by using product
families. platforms.
Companies can This
offerwill lower products
distinct the cost by sharing
of the product
modules and product
across increase production
families by flexibility. Companies
using product can also upgrade
platforms. and rede-
This will lower the cost of
sign products for future generations.
the product and increase production flexibility. Companies can also upgrade and redesign
The standard entities and differentiated entities are balanced in the modular struc-
products for future generations.
ture of product platforms. For instance, nine modules are identified in the module identi-
fication matrix in theentities
The standard andelectric
case of the differentiated
toothbrush. entities are balanced
The electric toothbrushinisthe modular structure
designed
of
on a single platform with common entities utilized in all three variations, as indicated inidentification
product platforms. For instance, nine modules are identified in the module
matrix in the
Figure 11. Thiscase of the
platform electric
has toothbrush.
been expanded The electric
to include producttoothbrush
families suchisasdesigned
young on a single
travelers, and families. From this platform, the variants can be developed as
platform with common entities utilized in all three variations, as indicated in Figure 11.
•
This For young, has
platform an exchangeable
been expanded cover to
and a circuitproduct
include board with a timersuch
families can used;
as young travelers, and
• For families, high-performance batteries and separate baby brush heads can be used;
families. From this platform, the variants can be developed as
• For travelers, a chargeable battery with quick charging can be used.
Common modules Product Families

Standard Entities Product Platforms
(based on variants)
Electric Motor
module
Battery module
Young
-Exchangeable cover
-CB with timer function
Charger Module -CB with variable speed
Brush head module

Family
-High performance battery
PCB Module Plateform 1 -Baby Brush head
Switch Module
Traveller
Transmission -Chargeable battery
-Quick charger
Module -CB with Indication when
charged
Styling Module
Chasis Module
Figure 11.
Figure 11.The
Theelectric toothbrush’s
electric common
toothbrush’s modulesmodules
common are used to
aredevelop
used toproduct platforms
develop to platforms to
product
address the three market demands.
address the three market demands.
4. Sustainable Flexible Manufacturing System—Product-to-Process Relationships
The product’s architecture supports the product and manufacturing process relation-
ships. These relationships can be developed concurrently, thus enabling product features
to be linked to the manufacturing setup. Thus, when a modular architecture is developed,
the factory can be reorganized accordingly, or reconfiguration is possible.
In the 3D printer case (Table 8), the manufacturing setup is based on internal and
• For young, an exchangeable cover and a circuit board with a timer can used;
• For families, high-performance batteries and separate baby brush heads can be used;
• For travelers, a chargeable battery with quick charging can be used.
4. Sustainable Flexible Manufacturing System—Product-to-Process Relationships

The product’s architecture supports the product and manufacturing process relation-
ships. These relationships can be developed concurrently, thus enabling product features
to be linked to the manufacturing setup. Thus, when a modular architecture is developed,
the factory can be reorganized accordingly, or reconfiguration is possible.
In the 3D printer case (Table 8), the manufacturing setup is based on internal and
external factors derived from the module drivers. From the analysis of the 3D printer,
the main drivers for internal setup, i.e., production, are related to carryover and common
units because they have higher weightage in the MIM. Similarly, the main drivers for
the external factors are more related to supplier availability, process/organization, and
service maintenance.
Table 8. Structure of the manufacturing process based on the modularization of a 3D printer.
Weight from
Factors That Determine Structure of
S.Nr Module Driver Property Module
Manufacturing Setup Manufacturing Process
Indication Matrix
1 Carryover Long life-cycle 38 Heavy investments possible
Internal More number Automation possibility
2 Common unit 87
of parts creates an economy of scale
3 Service/maintenance After-sale service 30 Ease of assembly
4 Supplier availability Quality 31 Exploit supplier capability
External
Group similar parts
Process design for
5 Process/organization 45 operations together,
manufacturing parts
increase productivity
For instance, parts such as the fan and stepper motor are identified as carryover
(specific functions can carry over to different products, and no technology changes are
expected). Similarly, in the process/manufacturing domain, more parts such as the extruder,
support system, and power supply are identified in the common unit (involves parts that
are identical in all products and used in several versions). Therefore, product and process
relationships can be identified for a sustainable flexible manufacturing system by applying
modularity approaches at the system design level.
In the case of the electric toothbrush, as given in Table 9, the manufacturing setup is
based on internal and external factors derived from the module drivers. From the analysis
of the toothbrush, the main drivers for internal setup, i.e., production related to carry-over
and common units, as they have higher weightage in the MIM. Similarly, the main drivers
for the external factors are more related to variance, supplier availability, and service
maintenance. This way, manufacturing requirements at the system level can be identified
for each module. By modularization, companies can structure their manufacturing setups
and concurrently undertake their development activities.
Table 9. Structure the manufacturing process based on the modularization of an electric toothbrush.
Weight from
Factors That Determine Structure of
S.Nr Module Driver Property Module Indication
Manufacturing Setup Manufacturing Process
Matrix
1 Carry over Long life-cycle 63 Heavy investments possible
Internal Increased yearly Automation possibility,
2 Common unit 69
volumes create economies of scale
Flexible material handling
3 Variance Many different parts 72 system and
planning resources
External
4 Supplier availability Quality 54 Exploit supplier capability
5 Service maintenance After-sale service 27 Ease of assembly
The comparative analysis of the two manufacturing products indicates that both
haveThe comparative
higher analysis ofcommon
scores for carry-over, the two unit,
manufacturing
service andproducts indicates
maintenance. that score
A higher both
have higher scores for carry-over, common unit, service and maintenance.
for common unit indicates that automation is possible for those modules to achieve econ- A higher
score
omiesfor
of common
scale. Bothunit indicates
products thatease
have automation is possible
of assembly due tofor thosescores
higher modules
for to achieve
service &
economies
maintenance.of scale. Both driver,
A module products have
i.e., ease ofavailability
supplier assembly due to higher
in both scores
products, for service
indicates the
& maintenance. A module driver, i.e., supplier availability in both products, indicates the
availability of suppliers to improve quality. However, a higher score for module driver-
availability of suppliers to improve quality. However, a higher score for module driver-
process/organization in 3D printer means that process design of manufacturing parts is
process/organization in 3D printer means that process design of manufacturing parts
possible, i.e., grouping similar parts with the same manufacturing process to increase
is possible, i.e., grouping similar parts with the same manufacturing process to increase
productivity. While in the case of the electric toothbrush, a flexible material handling sys-
productivity. While in the case of the electric toothbrush, a flexible material handling
tem is required to manufacture the three variants of young, traveler, and family.
system is required to manufacture the three variants of young, traveler, and family.
5. Framework
5. Framework for for Information
Information and and Decision-Making
Decision-Making for for Industry
Industry 4.04.0 Solutions
Solutions
Based on
Based on the
the information
information and and the
the decision
decision models
models using
using product
product architectures,
architectures, com-
com-
panies can make strategies in their business models to handle
panies can make strategies in their business models to handle the challenges of the challenges of shorter
shorter
time to
time to market,
market,complexity
complexityissues,
issues,and
andproduct
product life cycle
life issues
cycle to implement
issues to implement Industry 4.0
Industry
strategies
4.0 effectively.
strategies effectively.
Modular approaches
Modular approaches can can bebe used
used toto develop
develop aa basicbasic skeleton
skeleton ofof decision-making
decision-making
model at various business levels. This study develops a method that supports thethe
model at various business levels. This study develops a method that supports model-
modeling
ing of relationships from function to form at multiple levels and enables
of relationships from function to form at multiple levels and enables customization for customization
for sustainable
sustainable flexible
flexible manufacturing
manufacturing system
system in Industry
in Industry 4.0.4.0. Furthermore,
Furthermore, from
from thethe anal-
analysis
ysis
of ofcase
the the case studies,
studies, a decision-making
a decision-making model
model is developed
is developed (Figure
(Figure 12)aas
12) as a guideline
guideline for
for new
new business
business models
models thatthat
can can be used
be used in Industry
in Industry 4.0 scenarios.
4.0 scenarios.
Modular product
Front end issues architectures Back end issues
Customer Funtion into Modules System structure with Process Logistics

domain Structure Identification interfaces domain domain
Quality
function System Structure the Resourse
Modularization System allocation
deployment Architecting Manufacturing
MIM architecture Suppliers
process
availability
Product definition Process design Supply chain design

Product design
Figure 12. Based

Figure 12. Based on
on the
the proposed
proposed method,
method, aa framework
framework for
for decision-making
decision-making at
at different
different levels
levels to
to
implement a flexible manufacturing
manufacturing system.
system.
As shown in Figure 12, front-end issues are more related to customer requirements,
market segmentations, and how to translate requirements into technical specifications us-
ing quality function deployment and system architecture approaches. From this frame-
work, the industry can have solutions to apply to certain customer requirements coming
from the Internet of Service and have an edge in defining company strategy and the way
As shown in Figure 12, front-end issues are more related to customer requirements,
market segmentations, and how to translate requirements into technical specifications using
quality function deployment and system architecture approaches. From this framework,
the industry can have solutions to apply to certain customer requirements coming from
the Internet of Service and have an edge in defining company strategy and the way to
implement it while pursuing Industry 4.0 solutions.
The back-end issues are associated with the process domain and logistics domain,
as shown in Figure 12. While the system architecture supports the structuring of the
manufacturing process and allocation of resources with suppliers’ availability, as given in
Table 8. The supplier availability, service and maintenance are related to the organizational
effects of modularization. As illustrated in Table 8, service and maintenance are related
to after-sale service, supplier availability is related to quality, and process organization
refers to the fact that parts of the product that require the same production process can
be combined into a module that might improve the efficiency of the production process.
Furthermore, the modular design enables the postponement of parts production to later
stages of supply chain management, making it possible to assemble parts as per the
customer’s requirements in different geographical locations. This will facilitate the industry
to make a strategy for production planning and supply chain management, as shown in
the back end of the framework in Figure 12.
The proposed framework can be used by applying Industry 4.0 technologies to support
advanced manufacturing. For example, digital twins (DT) technology offers a way to test
products using models in a virtual environment rather than physically. DT can enable
the flow of information from the front end (product information) and from the back
end (process and supply chain design) to optimize the concept of the Modular Product
Architecture Framework in product design.
The core of a digital twin is the virtual models to reproduce the geometry, physical
properties and behaviors. The information at the front end (see Figure 12) is the customer
requirements, and product specifications can be utilized for the digital twin product at
the system design level. Then modeling and simulations of the product are performed for
system behavior analysis. After the system design, component or module design can be
initiated in DT. The information from the module indication matrix (MIM) in the framework
can be utilized in the digital twins to initiate module design prototypes. Next, the informa-
tion from the front end and modular product architecture can be used to develop the digital
twin production. In addition, the information in the process design, such as structuring
the manufacturing, can be used to develop digital twin production. The production DT is
critical to implementing factory automation and advanced manufacturing technologies.
The Quality Function Deployment Matrix of the proposed framework can be improved
by using the performance digital twin utilizing customer feedback through the Industrial
Internet of Things (IIoT). Each digital twin builds on and provides feedback to the other
digital twin. The digital twin reduces the time and cost of developing and manufacturing
products by enabling more robust designs and reducing product costs. Further, the design
improvements enable efficient manufacturing processes and technologies.
Software modules are based on different functions required by customers with stan-
dardized interfaces—that is, to allocate different functions to software modules and then
implement them in software code. It is possible to move the software solution from one
hardware to another, called hardware portability. If the software is not flexible that does not
scale well with the hardware. However, with the software modules in place, it is possible
to enable hardware portability and scalability.
Greater flexibility through the combination of pre-configured units via standardized
interfaces is possible through modular product architectures. This supports a flexible
material handling system that would pave the way for decentralized control based on
cyberphysical systems. These systems can facilitate that assembling is not controlled
centrally, but self-organized and decentralized. A CPS can control both highly automated
and manual processes.
6. Discussion and Implications

In the Industry 4.0 scenario, machines, products, and operators in a factory are all
connected to the Internet of Things (IoT). The Cyber-Physical Systems (CPS) in each factory
can create and test virtual prototypes of a product, allowing for quick feasibility, drafting,
and quoting following customer-specific requests. Companies are linked to their customers
and each other in an ecosystem via the Internet of Services (IoS), which simplifies business
processes for customers and provides an infrastructure for a shared value chain. These
actions would benefit from modular architectures, allowing companies to quickly develop,
produce, and market new products. These approaches create standardized interfaces that
carry and advance company-specific strategies.
In order to make quick changes in the manufacturing setup, such as easily upgradable
and reconfigurable machines, cells or plants, this framework supports the development
of modular manufacturing architectures. The architecture of the manufacturing system
must be based on exchangeable mechatronic modules. With the combination of electrome-
chanical and embedded systems and vertical and horizontal integration of the whole
system, including manufacturing, the system could be adopted according to the variable
requirements, even with a lot size one.
The proposed method supports how to develop product architecture for a flexible
manufacturing system. These architectures allow flexibility to adapt to changing require-
ments that will efficiently support Industry 4.0 solutions. Modular products lead to product
platforms and families that facilitate customization and are sustainable. Product platforms
are sets of common components, modules, or parts from which derivative products can be
developed. For example, Volvo’s production strategy aims to ensure commonalities across
assembly plants. This new method of vehicle design makes it possible to build several
car models from a common ‘platform.’ The purpose was to achieve such advantages as
shortened lead times, higher production efficiency, and flexibility in model changes.
One of the modern-day challenges to manufacturers is the responsiveness required
by the markets. This issue is handled through reconfigurable manufacturing systems
(RMS), as modularity is one of its characteristics [55]. RMS is a responsive manufacturing
system whose production capacity can be adjusted to changes in market demands, and its
functionality is adaptable to new products [11]. Part of the family identified in the modular
architectures is mapped to the machining functions. Machine tool parts are identified based
on the machining functions required for these parts. These tool parts are grouped into
machine modules for machining a particular part of the family. In this way, reconfigurable
machine tools (RMT) can be designed to give quick responses to the varying demands of
the markets.
Modular designs enable companies to outsource modules to suppliers that improve
the overall quality and management in the development process, as the suppliers are
specialists in their respective domains. For example, Dell computers offer customized
solutions with processors supplied by the Intel Company. Soon, companies may outsource
product assembly to customers. Thus, customers could assemble and upgrade the products
of their choice based on technological advancements and changing requirements.
Modular innovation strategies will complement the latest technologies, such as the
Internet of Things (IoT), 3D printing, and virtual inventories envisioned by Industry
4.0. Modular design will enable the postponement of parts production to later stages of
supply chain management, making it possible to manufacture products using 3D printers
resulting in lower inventories and costs. This has been observed during the COVID-19
pandemic as some companies adopted additive manufacturing.
Managerial Implications
Industries are facing challenges to achieving sustainability on the basis of technological
development. However, the improvement is not possible without huge investment and
capital. With mass customization strategies, managers can focus on providing distinct
functionality in the products that can be offered to the customers. As a result, managers
may concentrate on improving their core technical competencies and R&D emphasis to
promote product innovation for sustainable development with minimum cost.
Adopting a modular design approach has several benefits. The modular design
enables easier administration. More resources can be allocated at the beginning of product
development. This method allows for concurrent product development. Firms can also
employ modular architecture and platforms to structure their manufacturing processes.
The assembly process and required manufacturing resources can be recognized early in
the design stage by determining the architecture and required interactions between the
modules. Automation is a viable option for common unit parts to achieve economies of
scale. It is evident from the analysis that the necessary resources can be identified earlier in
the design stage.
7. Conclusions
Innovation, technology development, and R&D are a way towards sustainability.
Product and process level re-engineering to improve sustainability performance from
further integration of modular product architecture concepts and methods. This study
contributes to the development of a sustainable flexible manufacturing system for the
Industry 4.0 environment, where a method is proposed to develop modular product
architecture. This architecture identifies the product modules and their interfaces, as that
knowledge is being used to identify the product and manufacturing relationships. These
relationships can be developed concurrently enabling product features to be linked to
the manufacturing setup. Thus, when a modular architecture is developed, the factory
has to be reorganized accordingly. By identifying the architecture and required interfaces
between the modules, the assembly process and the necessary manufacturing resources
can be identified early in the design stage. For instance, a standard module that is common
in all versions of the product family can be used to structure the manufacturing process,
i.e., utilizing automation in a factory to achieve economies of scale. Thus, from the above
aspects, the overall cost can be reduced for a sustainable manufacturing system.
This study proposes a method using analysis and synthesis to develop product ar-
chitecture, platforms and a decision-making model. First, the customer requirements are
translated into system-level specifications, i.e., the main functions are decomposed into
subfunctions that are mapped on subsystems. Then, these subsystems are mapped into
the components to identify technical solutions. Afterward, the technical solutions are
evaluated against the module drivers in the module interaction matrix to identify modules.
The modules are combined to develop the modular architecture of the product along with
the interfaces. Additionally, the decomposition process identified commonality instances in
the product architecture, which can be utilized for the development of product platforms
and product families. Finally, modular architecture has been used to identify the product
and process relationships that aid in designing a flexible manufacturing system.
Modular architectures allow companies to quickly develop, produce, and market
new products. This approach creates standardized interfaces that carry and advance
company-specific strategies. In the 3D printer case study, nine modules were identified in
the module identification matrix. With these modules, one platform was developed that
comprises common entities used in all four variants of the 3D printer. This platform is
further extended to product families. Variants were identified mainly in terms of physical
components such as in the nozzle, bed area, frame and user interface.
In the Module Indication Matrix of the electric toothbrush, seven of the most weighted
technical solutions, along with chassis and styling, were chosen to develop nine modules.
In the MIM of the electric toothbrush, there are big totals for the module drivers such as
common unit, carryover, various specifications and separate testability. This indicates a
mature product with variants availability and acceptable quality as a result of separate
testability. A high carryover score indicates more technical solutions for next-generation
products. Score by different specifications and styling represents external factors related
to the user’s requirements. The electric toothbrush is designed on a single platform that
has common entities utilized in all three variations. This platform has been expanded to
include product families such as young, traveler, and family.
Using this method, the designers can identify a maximum number of standard compo-
nents required and develop product families with minimal changes in architecture. The
product architecture in the case studies can be altered by redesigning and using new tech-
nology in modules to develop product platforms and product families. Customization can
be used to generate more variants in the product using product platforms. In this way,
companies can make derivative products for the markets and generate more innovations.
This research also addresses the aspect of sustainable design and manufacturing. The
sustainable modular product architecture contributes to enhancing product recovery pro-
cesses by recycling and reusing modules without full disassembly at the component or
material levels. It results in less environmental harm from landfills and reduced usage of
natural resources. In this study, the MIM analysis is used to reconstruct the architecture of
a commercial product into a modular architecture. The sustainable modular drivers, specif-
ically interface complexity, upgrading, recycling, and manufacturing process similarity, are
utilized to drive sustainable modular design.
Author Contributions: Conceptualization, M.Z.Z. and S.-J.Y.; methodology, T.H. and M.S.H.; soft-
ware, S.B.K. and R.A.; validation, M.A., R.A.; formal analysis, T.H. and M.Z.Z.; resources, M.O.
and S.B.K.; data curation, M.S.H. and S.B.K.; writing—original draft preparation, T.H. and M.O.;
writing—review and editing, M.Z.Z., S.-J.Y., M.A. and R.A.; supervision, S.-J.Y. All authors have read
and agreed to the published version of the manuscript.
Funding: This work was supported by the Technology Innovation Program (or Industrial Strategic
Technology Development Program-material part package type), 20015986, funded by the Ministry of
Trade, Industry and Energy (MOTIE), Republic of Korea and the Department of Industrial Engineer-
ing, University of Engineering and Technology, Peshawar, Pakistan.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available on request.
Conflicts of Interest: The authors declare no conflict of interest.
Appendix A
Table A1. Customer requirements data collection results—3D printer.
Important Values
S# Customer Needs from 3D Printer
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20
1 Less time 8 8 10 10 6 10 10 8 7 6 8 6 6 10 7 9 10 8 10 10
2 Easy to use 8 7 7 4 9 7 7 7 7 5 9 8 10 8 10 10 9 8 8 10
3 Safety 8 9 10 10 9 10 10 10 8 8 9 9 10 10 5 7 7 10 10 9
4 Low price 10 10 10 8 10 10 9 10 8 8 10 8 10 10 8 10 10 10 9 10
5 Surface finish 9 10 9 10 9 10 10 10 10 10 10 10 9 10 9 9 9 10 10 10
6 Easy maintenance 9 9 8 7 6 7 4 8 8 7 7 8 9 3 9 7 6 9 9 9
7 Part size 5 3 8 7 4 4 5 4 7 3 6 3 5 9 9 6 5 4 6 6
8 Lesser power usage 7 8 5 3 7 3 5 4 9 6 5 8 5 10 9 9 6 4 7 9
9 Multiple materials 4 9 10 6 7 6 7 4 8 6 6 8 4 9 2 5 5 3 8 8
10 Connectivity 7 6 8 9 8 3 5 6 8 7 8 7 6 3 3 3 4 5 8 6
11 Storage capacity 3 8 8 6 7 6 6 5 8 8 8 8 8 6 5 4 5 9 4 4
Table A2. Customer requirements data collection results—the electric toothbrush.
Important Values
S# Customer Needs from 3D Printer
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20
1 Ease of use 7 10 10 10 6 10 10 9 7 6 8 10 6 10 9 9 10 8 10 10
2 High impact resistance 9 10 7 6 10 5 7 7 10 5 9 8 10 8 10 10 9 10 8 10
3 Long lifetime 10 9 9 10 9 10 10 10 8 8 9 9 10 10 5 8 7 10 10 9
4 Low price 10 9 10 7 10 10 9 10 9 8 10 8 10 10 8 10 10 10 9 5
5 Variable speed 9 10 9 10 9 6 6 10 8 7 7 10 9 6 9 9 7 10 5 10
6 Indication when charged 10 9 9 7 10 7 4 8 10 7 9 8 9 3 10 7 6 9 9 9
7 Long battery life 5 8 8 7 10 4 5 10 7 3 9 7 10 9 9 6 9 4 6 9
8 Quick battery charging 6 8 6 3 7 3 5 4 9 6 5 8 5 10 9 9 6 4 7 9
9 Exchangeable cover 3 9 10 5 7 6 7 4 8 6 6 8 4 9 2 5 5 3 8 8
10 Easy up-gradation 7 6 8 9 8 3 5 6 8 7 8 7 6 3 3 3 4 5 8 6
11 Timer function 3 8 5 6 7 6 6 5 8 8 5 8 4 6 5 4 3 9 4 4
12 Easy maintenance 4 5 7 2 8 6 5 4 8 6 4 2 3 6 7 9 2 7 4 5
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Sustainability 2023, 15, 910. https://doi.org/10.3390/su15020910 https://www.mdpi.com/journal/sustainability

Topics (Key Technologies and

According to Ngjeqari [44], the 4th Industrial Revolution is an enabler of sustainable

2.1. Method to Develop Product Architecture

2.2. Steps in the Proposed Method

3. Application of the Proposed Method

From the user’s perspective, requirements include the following:

3.1.1. Analyze Requirements and Product Attributes by Applying Quality Function

Table 2. Importance of customer requirements for 3D printer.

S. No Customer Requirements Importance Values

Relationship between Demands and Attributes:

3.1.2. Hierarchical Decomposition Using System Architecting to Identify Functions and

To move To control To print To support

Motion control User interface Power supply

Threaded Servo End Control Cold Transfor Print Reel

Easy maintenance Attributes 4 3 3 18

Board Cover Brush Head

Motor Control Brush Head

Circuit Board Oscillator

Chassis Transformer Electrical

Electrical MotorGear Box

Gear Box Transformer

Head Brush Head Oscillator

Circuit Board Chassis

Cover End Cover

BoxOn/off Switch Base

User interface Axle Assembly

Total End Cover

Brush Head BrushChargeable

Base Board BaseOscillator

Circuit BoardCircuit Board

Axle Assembly Chassis

LED BaseCircuit Board

Base BaseBase LED

Base Oscillator Charger

Electrical Motor Gear

LED Circuit Board

Timer LED Timer

Five modules, along with weightage

2 per. Mov. Avg. (Weightage of each module)

Figure 4. Nine of the modules with their weight and variants.

3.1.5. Product Architecture: 3D Printer with Modules and Interface Design

Cold End Nozzle

User interface module

Common modules Product families

A global “small appliance” manufacturer has decided to introduce a new global

3.2.1. Analyze Requirements and Product Attributes by Applying Quality Function

3.2.2. Hierarchical Decomposition Using System Architecture to Identify Functions and

Electric tooth brush

To Control To rotate To supply power To support

Circuit Motor Axle Electrical Chargible Transform Brush

On/off Switch Electrical Motor

LED Control Transformer

Motor Control End Cover

On/off Switch Gear Box

Circuit Board Oscillator

LED Board Charger

Axle Assembly Charger

Motor Control Cover

Brush Head Motor

Board Board Base