Skip to main content
SpringerLink
Log in

Integrating lean and other strategies for mass customization manufacturing: a case study

  • Published:
Journal of Intelligent Manufacturing Aims and scope Submit manuscript

Abstract

Mass customization (MC) manufacturing requires high flexibility to respond to customer needs in a timely manner. Lean manufacturing principles can be easily applied to situations with low levels of MC. However, as the degree of customization increases and customer involvement occurs earlier in the design and fabrication stages, the direct application of lean principles to maintain flow and low levels of inventory becomes difficult. This paper presents a framework to show how other strategies such as Quick Response manufacturing/POLCA, Theory of Constraints, Flexible/Reconfigurable Manufacturing Systems, etc. can be integrated with lean in MC environments. A case study of boat mass customizer is then used to demonstrate how their operations are transformed by for more efficient MC. Simulation models are used to compare pre- and post-improvement performance.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  • Badurdeen, F., & Liyanage, J. P. (2009). Promoting sustainability through mass customization: A framework and directions for future research. International Journal of Sustainable Manufacturing. Accepted.

  • Badurdeen F., Masel D. (2007) A modular minicell configuration for mass customization manufacturing. International Journal of Mass Customisation 2(1/2): 39–56

    Article  Google Scholar 

  • Barnett L., Rahimifard S., Newman S. (2004) Distributed scheduling to support mass customization in the shoe industry. International Journal of Computer Integrated Manufacturing 17(7): 623–632

    Article  Google Scholar 

  • Berman B. (2002) Should your firm adopt a mass customization strategy?. Business Horizons 45(4): 52–60

    Article  Google Scholar 

  • Bicheno J. (2000) The lean toolbox (2nd edn). PICSIE Books, England

    Google Scholar 

  • Boynton A. C., Victor B., Pine B. J. II (1993) New competitive strategies: Challenges to organizations and information technology. IBM Systems Journal 32(1): 40–64

    Article  Google Scholar 

  • Brink, T., & Ballard, G. (2005). Slam—A case study in applying lean to job shops. ASCE Construction Research Congress. 5–7 April 2005, San Diego, CA.

  • Buyukozkan G., Dereli T., Baykasoglu A. (2004) A survey on the methods and tools of concurrent new product development and agile manufacturing. Journal of Intelligent Manufacturing 15: 731–751

    Article  Google Scholar 

  • Byrkett D. l., Ozden M. H., Patton J. M. (1988) Integrating flexible manufacturing systems with traditional manufacturing, planning and control. Journal of Production and Inventory Management 29: 15–21

    Google Scholar 

  • Chan F. T. S., Chan H. K. (2004) A comprehensive survey and future trends of simulation study on FMS scheduling. Journal of Intelligent Manufacturing 15(1): 87–102

    Article  Google Scholar 

  • Clarke C. (2005) Do you want to be lean or agile?. Manufacturing Computer Solutions 11(3): 14–15

    Google Scholar 

  • Co H. C., Jacobson S. H. (1994) Kanban assignment problem in serial just-in-time production systems. IIE Transactions (Institute of Industrial Engineers) 26(2): 76–85

    Google Scholar 

  • Da Silveira G., Borenstein D., Fogliatto F. S. (2001) Mass customization: Literature review and research directions. International Journal of Production Economics 72(1): 1–13

    Article  Google Scholar 

  • Duray R., Ward P. T., Milligan G. W., Berry W. L. (2000) Approaches to mass customization: Configurations and empirical validation. Journal of Operations Management 18(6): 605–625

    Article  Google Scholar 

  • Fernandes N. O., Carmo-Silva S. (2006) Generic POLCA-A production and materials flow control mechanism for quick response manufacturing. International Journal of Production Economics 62(1–2): 119–132

    Google Scholar 

  • Ford H. (1988) Today and tomorrow. Productivity Press, Oregon

    Google Scholar 

  • Gaury E. G. A., Pierreval H., Kleijnen J. P. C. (2000) An evolutionary approach to select a pull system among Kanban, Conwip and Hybrid. Journal of Intelligent Manufacturing 11: 157–167

    Article  Google Scholar 

  • Gilmore, J. H., & Pine, J. B. (1997). The four faces of customization (pp. 91–101). Harvard Business Review.

  • Goldratt E. M. (2004) The goal: A process of ongoing improvement. Highbridge Company, Minnesota

    Google Scholar 

  • Huang, C., Tseng, T., & Chang, H. (2005). A novel approach to lean control. In Proceedings of IIE Annual conference and Exposition, 14–18 May 2005, Atlanta, GA.

  • Klusewitz, G., & Rerick, R. (1996). Constraint management through the drum-buffer-rope system. In Proceedings of IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop, (pp. 7–12). 12–14 November 1996, Cambridge, MA.

  • Koren Y., Heisel U., Jovane F., Moriwaki T., Pritschow G., Ulsoy G., Van Brussel H. (1999) Reconfigurable manufacturing systems. Annals of the CIRP 48(2): 527–540

    Article  Google Scholar 

  • Krishnamurthy R., Yauch C. A. (2007) Leagile manufacturing: A proposed corporate infrastructure. International Journal of Operations & Production Management 27(6): 588–604

    Article  Google Scholar 

  • Lampel J., Mintzberg H. (1996) Customizing customization. Sloan Management Review 38(1): 21–30

    Google Scholar 

  • Liker J. K. (2003) The toyota way. McGraw-Hill, Wisconsin

    Google Scholar 

  • Mason-Jones R., Naylor B., Towill D. R. (2000) Lean, agile, or leagile? matching your supply chain to the marketplace. International Journal of Production Research 38(17): 4061–4070

    Article  Google Scholar 

  • Mehrabi M. G., Ulsoy A. G., Koren Y. (2000) Reconfigurable manufacturing systems: Key to future manufacturing. Journal of Intelligent Manufacturing 11: 403–419

    Article  Google Scholar 

  • Michel R. (2002) Multiple paths to lean. MSI 20(11): 54–57

    Google Scholar 

  • Monden Y. (1998) Toyota production system (3rd edn). Engineering and Management Press, Georgia

    Google Scholar 

  • Moser K. (2007) Mass customization strategies-development of a competence-based framework for indentifying different mass customization strategies. Lulu Enterprises, Inc., Morrisville, NC

    Google Scholar 

  • Naylor J. B., Naim M. M., Berry D. (1999) Leagility: Integrating the lean and agile manufacturing paradigms in the total supply chain. International Journal of Production Economics 62: 107–118

    Article  Google Scholar 

  • Ohno T. (1988) Toyota production system: Beyond large-scale production. Productivity Press, New York

    Google Scholar 

  • Pine J.B. (1993) Mass customization: The new frontier in business competition. Harvard Business School Press, MA

    Google Scholar 

  • Selladurai R. S. (2004) Mass customization in operations management: Oxymoron or reality?. Omega 32(4): 295–300

    Article  Google Scholar 

  • Shingo S. (1988) Non-stock production: The shingo system for continuous improvement. Productivity Press, Oregon

    Google Scholar 

  • Shuaib, M., & Badurdeen, F. (2009). Job scheduling in associative parallel machines to minimize average flow time. In Proceedings of the Indian Sub-continent Decision Sciences Institute Conference (pp. 102–112) 2–5 January 2009, Mumbai, India.

  • Steele D. C., Philipoom P. R., Malhotra M. K., Fry T. D. (2005) Comparisons between drum-buffer-rope and material requirements planning: A case study. International journal of Production Research 43(15): 3181–3208

    Article  Google Scholar 

  • Stratton R., Warburton R. D. H. (2003) The strategic integration of agile and lean supply. International Journal of Production Economics 85: 183–198

    Article  Google Scholar 

  • Suri, R. (1994). Common misconceptions and blunders in implementing quick response manufacturing. Technical Paper—Society of Manufacturing Engineers 1994, (pp. 1–23).

  • Suri R. (1998) Quick response manufacturing: A company wide approach to reducing lead times. Productivity Press, Oregon

    Google Scholar 

  • Swaminathan J. M. (2001) Enabling customization using standard operations. California Management Review 43(3): 125–135

    Google Scholar 

  • Takahashi K., Hirotani M., Hirotani D. (2005) Comparing CONWIP, synchronized CONWIP, and Kanban in complex supply chains. International Journal of Production Economics 93–94: 25–40

    Article  Google Scholar 

  • Ulrich K., Tung K. (1991) Fundamentals of product modularity. Issues in Design Manufacture/Integration 39: 73–79

    Google Scholar 

  • Wantuck K. A. (1989) Just in time for America. Edwards Brothers Inc, Michigan

    Google Scholar 

  • Womack J. P., Jones D. T. (1996) Lean thinking. Simon & Schuster, New York

    Google Scholar 

  • Womack J. P., Jones D. T., Roos D. (1991) The machine that changed the world. HarperCollins Publishers, New York

    Google Scholar 

  • Yusuf Y. Y., Adeleye E. O. (2002) A comparative study of lean and agile manufacturing with a related survey of current practices in the UK. Modeling, Planning and Scheduling of Manufacturing Systems 40(17): 4545–4562

    Google Scholar 

  • Zipkin P. (2001) The limits of mass customization. Sloan Management Review 42(3): 81–87

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. University of Kentucky, Lexington, KY, USA

    Brandon Stump & Fazleena Badurdeen

Authors
  1. Brandon Stump
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fazleena Badurdeen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Fazleena Badurdeen.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Stump, B., Badurdeen, F. Integrating lean and other strategies for mass customization manufacturing: a case study. J Intell Manuf 23, 109–124 (2012). https://doi.org/10.1007/s10845-009-0289-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10845-009-0289-3

Keywords

Search

Navigation