Modular Design: Product Architecture Value-add

One of the disciplines I learned as a network architect was to explore alternative functional architectures... that is, to be deliberate in the choice of where a function is performed in the network.  For example, restoration on failure of a fiber optic link is a function that can be performed centrally (manual restoration coordination, or automated restoration using an operational support system) or in a distributed manner (rerouting in switching or routing vehicles or more rapid restoration using 1-1, ring or mesh transport systems.) Each approach has its strengths and weaknesses, some work well together and many do not.

In product design, electronic systems architects generally do a good job of thinking through the functional architecture because there is a tradition of modular design in both hardware (backplanes, boards/blades, daughter boards, etc.) and software (operating system, services, applications, stacks, frameworks, etc.)  However, in the design of mechanical systems, the modular approach is less traditional and sometimes counter-intuitive.  The benefits of standardization of parts and subassemblies are clear from a procurement and manufacturing perspective, however, for simple products the additional planning, coordination and overhead of modularization may not be justified, particularly where the volumes of a new product are hard to predict.

Modular design for mechanical products requires a change of thought... the designer should be planning for success and expecting larger volumes, product evolution and related products.  That is, the designer should be planning a product family over time, not just one product to solve one problem for one customer.  That approach will identify components of the product that will be common over the product family, components that will evolve over time, components that will need to change to address different scales of applications and components that should be customizable to address different operating environments and operational procedures.  The result will be a product family with many variations, built from a smaller number of components.

The pioneers of this type of design for mechanical products have been Scandinavian engineering and manufacturing companies.  There are good economic and cultural reasons for this discipline developing in these countries... design traditions are strong, but also, these companies recognized early that to create a sustainable differentiation in a global market where the competition has much lower labor and material costs, they needed to create designs that used material more efficiently, could be shipped more cost effectively and addressed fundamental customer problems in unique ways.  I find a walk through an IKEA store is an education in modular mechanical design and global competition.

What are your perspectives on modular design, particularly for mechanical products?  Do you own any Scandinavian products?  If so, why?