Short Course at University of Valladolid

RECONFIGURABLE MANUFACTURING – Product, Process, & Business Integration

Summer 2004
Instructor: Zbigniew J. Pasek, Ph. D., University of Michigan

Course Rationale and Objectives: Globalization creates both an opportunity and a challenge for
manufacturing companies. For established companies the opportunity is to sell products in any place on
the globe, and enhance the sales with the aid of the Internet. The challenge is to succeed in a turbulent
business environment, in which competitors have similar opportunities.
Globalization and the Internet originate another type of opportunity – to form start-up companies for
durable goods that are utilizing the Internet to enhance their sales (entrepreneurship). Since the core of
such start-ups is the innovative product, this course emphasizes creativity in designing products and
touches on preparing simple business plans.
There is a third possibility that unifies the two previous opportunities – to form a new subsidiary (or a
division) inside a large corporation to produce a new product within the company’s line of products. The
challenge is similar to that in forming a start-up, but it is easier in the finance aspect –– if the product is
appealing, the corporation will invest the resources.
This course aims at analyzing the technical and business dimensions of different manufacturing
paradigms, and emphasizing the integration between engineering and business:
• Developing innovative products having the variety to satisfy customers’ tastes and preferences
in different regional segments
• Developing a new type of reconfigurable manufacturing systems that have a production
capacity adaptable to market demand
• Developing responsive business models that take advantage of market opportunities and
enhance customer relationships.

Course Topics
1. Manufacturing Paradigms
Mass production, lean production, mass customization and personalized productio.
Models and principles of these paradigms.

2. Product Design in Global Environment

Creativity in product design. Design for Mass-Customization.
Modular architecture in product design.

3. Manufacturing Systems
Dedicated, flexible, and reconfigurable systems and machines.
Analysis of system configurations.

4. Business Issues
Agile, reconfigurable enterprises. Responsive business models. Workforce empowerment.
Finance models. Preparation of simple business plans.

Materials
1. Coursepack
2. Class slides
3. Occasional reading

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Course Requirements
We work in teams of four (4) students; whenever possible each coming from a different background (e.g.,
engineering, business, industrial experience, etc.). The instructors assign the teams.
• Before the first class, please fill the course form that enables us to form teams.
• The team assignment is to form a start-up company that produces a new innovative
product that fits mass-customization markets at a global scale. The team should
(1) Describe the products and its design,
(2) Elaborate on the manufacturing system that produces the product, and
(3) Prepare a simple business plan that includes (a) market analysis, (b) product design,
(c) layout of the production system, (d) strategic plan and company organization, and
(e) finance issues. This is the team main class project (70% of the grade).
Additional requirements include:
• Reading before class; part of the grade is given on class participation
• “Paradoxical Products” for creative thinking (tentative).
• Three team assignments (tentative).

Course Final Grade

70% - Team Project
10 % - Product Design: Presentation, Report, Response to comments
10 % - Product Manufacturing: Presentation, Report, Response to comments
10 % - Final Project Presentation
10 % - Grades given by team mates.
30 % - Final Project Report.
10 % - Class Participation: Presence and discussion.
20 % - Additional Assignments

Schedule
Date Description Chapter
Day 1 Course Overview & Organization 1
Introduction to Reconfigurable Systems
Day 2 Product Development Strategy 2
Customer Surveys and Product Specifications
Customized, Personalized & Reconfigurable Products
Day 3 Product Design Presentations
Mass Production & Lean Production 4
Analysis of Mass Customization 5
Traditional Manufacturing Systems 6
Day 4 Reconfigurable Manufacturing Systems 7
Reconfigurable Machines 8
System Configuration Analysis 9
Day 5 Product Manufacturing Presentations
Responsive Business Models 10
Financial Models
Day 6 Business plans
Globalization & manufacturing strategies
Day 7 Final Project Presentations
Class Summary 12

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