Modeling Platform-Based Product Configuration Usin
Modeling Platform-Based Product Configuration Usin
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XUEHONG DU {, JI A N X I N J I AO { *
and MITCHELL M. TSENG §
1. Introduction
Facing the buyers’ market, many industries are now shifting from mass production
to mass customization, which demands quick response to the needs of individual cus-
tomers with high quality and acceptable costs (Pine 1993). Platform-based product
configuration has received an increasing interest in recent years because, by sharing
components across products, a product platform lends itself to the ability to derive
a family of products that are tailored to individual customer needs along with reduced
lead time and costs (Meyer and Lehnerd 1997). The platform performs as a generic
umbrella under which product configuration manifests itself through variant derivation
within common product line structures. Earlier research often highlights successful yet
isolated empirical studies without attempt to discuss the more general modelling issue
surrounding this economically important class of engineering design problem
(Rothwell and Gardiner 1990, McGrath 1995, Sanderson and Uzumeri 1995, McKay
et al. 1996). To realize mass customization, the computerization and, eventually, auto-
mation of platform-based product configuration necessitates the formal representation
of a platform and the modelling of product variant derivation.
Towards this end, the present paper attempts to introduce graph grammar formal-
isms to product platform representation and variant derivation modelling. Owing to its
formality, executability, extensibility and generality in modelling and manipulation of
structural and non-structural information, the graph grammar approach has been
applied as a formal method to facilitate the characterization of design problems more
precisely (Mullins and Rinderle 1991). The generic term ‘graph grammars’ refers to a
variety of mathematical formalisms for specifying sets of graphs through manipulating
symbols representing graph vertices and edges. A graph re-writing system consists of
graphs (or starting graphs) and a set of operations (or productions) that can be applied
to manipulate the graphs. Graphs provide an expressive and versatile data representa-
tion. Typically, nodes represent objects or concepts, and edges represent relations
among them. If a system is modelled as graphs and the production rules for graph
operation are designed properly, as long as users apply the pre-defined productions
to manipulate a graph, then the graph produced will satisfy the characteristics of the
desired system model. All of the graphs that can be derived by applying productions
to the starting graph in certain order from the language of this graph grammar.
In the next section, key issues of platform-based product configuration and techni-
cal challenges of its modelling are discussed. Graph grammar concepts are then related
to platform representation and variant derivation modelling in section 3. Modelling
formalisms are developed in section 4, while in section 5 a case study of a power sup-
ply platform and related product customization is presented to illustrate the feasibility
and potential of graph grammars for platform modelling.
subsystems and interfaces developed to form a common structure from which a stream
of derivative products can be efficiently developed and produced’ (Meyer and Lehnerd
1997, p. 39). The major issue is to exploit the shared logic and cohesive architecture
underlying a product platform. One endeavour towards product platform development
is to design product families in the way of ‘stretching’ and/or ‘scaling’ (Rothwell and
Gardiner 1990). The development of Boeing 7XX aircrafts epitomizes such a design
practice (Sabbagh 1996). The robust design of product families is discussed in Chen
et al. (1996) and Simpson et al. (1996a, 1996b). Simpson et al. (1999) proposed a
product platform concept exploration method to facilitate the synthesis and exploration
of certain common product platform concepts that can be scaled to generate an
appropriate family of products. Siddique et al. (1998) employed graph grammars to
identify the common platform for a set of similar products and to specify possible
product portfolio supported by the platform. To facilitate platform-based product
family development, interface management is reported as a distinct process of defining
the physical interfaces between subsystems (Sundgren 1999). Set-based model is an
attempt to the formal representation of product platform design and manufacturing
processes (Finch 1999).
While prevalent understanding of product platform refers to those shared physical
components (Ulrich 1995), this research emphasizes its architectural implication—the
conceptual structure and overall logical organization of generating a family of pro-
ducts. In other words, a product platform is a structured system creating a variety of
products with shared core product technologies. The common elements may be shared
physical components, customization modules, standard designs, and/or rules for
generating custom designs. Such an architectural perspective in fact manifests the
platform-based product configuration.
3. Graph grammars
As a complex system modelling tool, graph grammars excel in describing struc-
tural information and dealing with the transformation and generation of elements in
graph morphisms. With respect to architectural modelling, graph grammar concepts
are summarized as follows.
150 X. Du et al.
Definition 6: A gluing is a special case of direct derivation from graph G to G0, where
Gl ¼ Kl and g: Kl!G, D ¼ G. Therefore gluing is a six-tuple: <G ¼ (Gr, K1, Kr, g, gr, T),
where Gr, Kr, gr, and T are the same as in definition 4. A gluing operation is defined by the
following procedure:
(1) Check whether Kl is a subgraph in G (i.e. g: Kl!G) and check the gluing
condition. If both conditions are fulfilled, go to step 2; and
(2) G0 is obtained by gluing of G and Gr at corresponding points.
Definition 7: An attribute calculation production is a three-tuple, <A ¼ (n, attr, f ), where
(1) n 2 N is a node in G whose attribute attr 2 a(n) will be altered; and (2) f is a node
attribute equation.
Definition 8: A production rule is a two 2-tuple, PR ¼ (<, p), where (1) < is manipulation
to be applied to the graph, < 2 {<G, <D, <A}; and (2) p: G!{TRUE, FALSE} is the
applicability predicate.
Compared with the general definition of production as given in Bunke (1982) and
Blostein et al. (1996), three operations defined in definition 4, definition 6, and defini-
tion 7 explicate graph manipulation in the context of architecture modelling. Definition
8 emphasizes the applicability of a manipulation and allows the extension of defined
manipulations. In other words, if other manipulations other than <G, <D, and <A are
needed, they can be easily added to the set <.
The programming of an attributed graph grammar was originally introduced by
Bunke (1977) and is summarized below.
Definition 9: Let P be a finite set of production rules, P P. A control diagram over P* is
a graph, with the set, P [ {I , F}, as node labels and the set, {Y, N, Either}, as edge labels.
Furthermore these conditions hold true: (1) there exists exactly one initial node nI labelled
with I; (2) there exists exactly one final node nF labelled with F; (3) there exists no edge
terminated with nI; and (4) there exists no edge originated from nF.
An example of the control diagram is shown in figure 2. Except the initial and
final nodes, all nodes are labelled with productions. To apply productions accord-
ing to the control diagram, we start with a production that is labelled as a direct
successor of the initial node and examine its applicability. This can be explained
using Y notations (Göttler 1983). Upon successful application of a production, a
Y-edge in the control diagram is tracked, whereas the tracking of the N-edge is
caused by the failure execution of a production. A derivation sequence stops when
the final node is reached. It may happen that there is a lack of an outgoing Y-edge,
although the production belonging to the actual control diagram node has been
successfully applied. In this case, the continuation of the current derivation
sequence is not defined and no graph will be generated. The analogous situation
arises when the considered production is not applicable and no out-going N-edge
exists. If more than one Y-edge/N-edge exists, leaving the same node in the control
diagram, any one can be chosen.
In some cases, certain variants have the same coupling/decoupling relationships as
the other parts of the product. Accordingly, in the control diagram, the productions
manipulating these variants possess the same predecessor and successor nodes; that
is, they are parallel. The pair of p1 and p2 in figure 3a exhibits such a situation.
Whenever the variants possess different coupling/decoupling relationships from the
other parts of the product, the productions manipulating these variants will not be par-
allel in the control diagram (e.g. p1 and p2 in figure 3b). In figure 3, M1 is independent
of any module manipulated through p3. However, M2 depends on that module. Once
M2 is manipulated, p3 has to be performed, if applicable.
Parallel productions are frequently encountered in product configuration, in parti-
cular when the high-level decomposition is involved. To represent this type of produc-
tion concisely, we introduce the concept of alternative production.
Definition 10: pk ¼ [O(Mk), pk] and pl ¼ [O(Ml), pl] are alternate productions, if
(1) M k and M l are variants of a generic module, M, 8 k, l 2 {1, . . . , K}, k 6¼ l;
(2) O(Mk) ¼ O(Ml); and
(3) pk 6¼ pl.
All alternative productions can be represented by a generic production,
P(M) ¼ { pk}. A generic production is defined for a generic module if all operations
of the productions are the same whereas the application conditions are different. In
the control diagram, a generic production is represented as a node with a self-looped
N-edge. Node 1 in figure 4a is labelled p1, which is the generic production
representing all alternative productions manipulating the variants of M1. The applica-
tion of productions according to the control diagram in figure 4a is described in
figure 4b, in which the dashed box highlights how alternative productions are applied.
When the preceding production of a generic production is successfully applied, one
of the alternative productions of this generic production should be executed. If it is
successfully applied, the derivation process will move to its successor node.
Otherwise, the second alternative production will be applied. This process continues
until all alternatives are experienced. In case none of them is applicable (i.e. all the
application conditions of alternative productions are false), the application of this
generic production then fails.
are finite sets of attributes for nodes and edges, respectively; (3) PR is a finite set of pro-
duction rules; (4) S is a set of initial graphs; and (5) CD is a finite set of control diagrams.
The distinction between terminal and non-terminal labels for either nodes or edges
is useful for non-programmed grammars, primarily in order to implicitly control the
stop of a derivation sequence. For programmed graph grammars, however, this distinc-
tion is no longer needed since control diagrams and control specifications provide
explicit tools for controlling the order of productions including the stop of a derivation
sequence.
Definition 12: Let GG be a programmed attributed graph grammar. The language of the
graph grammar consists of all a-graphs that can be derived by these steps: (1) start with
an initial graph; (2) apply productions in an order specified by the control diagram; and
(3) stop the derivation sequence when the final node in the control diagram is reached.
In most literature, graphs and productions are referred to as graph grammars no
matter whether a graph language is defined. Nevertheless, the graph language is
important in architectural modelling because it defines the generative power of a graph
grammar and consequently describes the design space that can be generated under the
architecture.
be dealt with using the application conditions of production rules. The application
sequence of production rules can be controlled by constructing control diagrams that
capture the complex relationships among modules.
its base product, and generic module M11, as well as the relevant production
rules. While compound generic modules are determined by their functions and sub-
modules, primitive generic modules are characterized by their variants and design
parameters. This implies a tree-like, hierarchical product structure with fixed modules
or primitive generic modules as leaves and compound generic modules as intermedi-
ary nodes. Such a phenomenon reveals the concept of node nesting in graph
formalisms.
5. Case study
A switching mode power supply platform, called FB65-T, is adopted in this case
study. The structure of switching-mode power supplies is depicted in figure 6. The
characteristics of the FB65-T platform include universal input, triple output, 65 W nor-
mal output power, and flyback converter. Based on market research, four categories of
most required customization are identified: the value of output voltages, the accuracy
of output voltage, the output protection scheme, and auto-recovery (AuR). The port-
folio of the FB65-T platform is planned as follows.
(1) Base product: þ5 V, 12 V, normal output accuracy, and short-circuit (SC)
protection.
(2) The variety of output voltage is achieved using the scaling method, where the
secondary turns are calculated according to certain equations.
(3) The variety of output accuracy is fulfilled using the swapping method. Either
multiple-output sensing or single-output sensing can be selected as the feed-
back circuit in accordance with the accuracy level specified by customers.
(4) As for the protection scheme, two points have to be highlighted. At a higher
level of decomposition, the protection circuit is a module that is relatively
independent of other parts of the system. However, the module itself can
be further decomposed into SC protection, over-voltage (OV) protection and
compensation submodules. In power supply realization, a protection module
may consist of the compensation submodule and any one or two of the
protection submodules.
(5) If the AuR feature is desired, a shut-down-on-overcurrent start-up circuit is
required to replace the boot-strap circuit.
Figure 7 gives the graphical representation of all modules and module classes in
platform FB65-T. GB is the base product of FB65-T. G2, G6, and G8 are the primitive
generic modules. G7 is a compound generic module. The variety of module G7 comes
from different combinations of G7.1 and G7.2 with respect to G7.3—the starting
graph (base product) of platform M7. Table 2 presents the algebraic representation
of a specific variant of switching power supplies.
The production rules defined for FB65-T are presented in table 3. Production rules
can also be expressed in graphical form. Figure 8 shows the left-hand and right-hand
sides of production rules PR2 and PR3. Figure 9 gives the Y notation of PR2. The
Y notation is also called a production graph, where the lower-left, lower-right and
upper corners are noted as Gl, Gr and Gc, respectively. The Gc in fact is the
context graph of the production rule. Edges across the branches of Y are embedding
transformations.
Figure 10 shows the control diagrams of platform FB65-T and its nested
platform M7. The control diagram of a platform defines the graph language of this plat-
form (i.e. all possible product variants generated from the platform). For instance,
there are three paths in the control diagram of M7. Therefore, three protection schemes
can be derived by applying PR4 and PR5 to the base product G7.3 in accordance with
the control diagram given by figure 10b.
The process of variant derivation follows the following steps: (1) let customers
enter their selections; (2) identify the longest applicable path in the control diagram
of FB65-T, noted as PATHFB65T ; (3) among all production rules along the
PATHFB65T , PR3 is associated with a compound module M7 that results in further
decomposition into primitive modules (such a situation indicates node nesting in graph
operations; therefore, the control diagram of M7 is invoked and its longest path is
identified, noted as PATHM7 ); and (4) executing production from node I to node F
along the PATHFB65T and PATHM7 . Then the required product variant can be
Platform-based product configuration 159
control diagram given in figure 10a and applying PR1, PR2, PR3 or PR6 consecu-
tively, a family of switching power supplies can be obtained. All variants in the family
possess common features such as 65 W, universal input, and triple outputs, and yet
meet specific requirements on output voltages, output accuracy, protection schemes
and auto-recovery.
The product platform of switching power supplies consists of given features,
optional features, variable feature values, the base product, optional modules,
production rules and control diagrams. The options include changing values of output
voltage, levels of output accuracy, protection schemes and the feature of auto-recovery
after failure. In the customer view, product variety is defined in terms of these
functional options. Then productions are applied to covert the functional specifications
to variant derivation in the technical view. The platform defined in the case study can
generate totally 20 members of the FB65-T family. The algebraic representation of
FB65-T platform is presented in table 5.
162 X. Du et al.
6. Discussion
Based on programmed attributed graph grammars, this paper develops a formal
representation of the platform and related variant derivation. The preliminary results
indicate that some of the characteristics of graph grammars closely map to product
platform characteristics. A graph grammar can be used to transform customer require-
ments to the design of product variants of a family. The product platform is presented
in two views (i.e. the customer and technical views). In addition to those given func-
tional features, optional features and variable feature values comprise the basis for
customer selection (i.e. customization) and thus achieve variety in the customer view.
The mapping of customer requirements from the customer view to the technical view
manifests itself through defining application conditions for production rules, which, in
cooperation with control diagrams, determine how a suitable variant is derived from
the base product of the platform. Graph grammars also provide a means to describe
the design space of a product platform by the graph language.
In this research, variety fulfillment is approached between the customer view and
the technical view, rather than between the function view and the structure view as
done by Siddique and Rosen (1999) and Schmiddt and Cagan (1997). The rationale
lies in that product platform representation focuses more on the organization of data
and knowledge than on the platform development process; that is, how a product
Product platform:
Given: {universal input; triple output; þ5 V; 65 W; RFI}
Options: {12/12 (1 þ 15%); normal output accuracy/high output accuracy;
short circuit protection/over-voltage protection/auto-recovery}
Customer view: PP ¼ (FG, FO, FV)
F G ¼ {F1, F2, F7} a(F3) 2 [12, 12 (1 þ 15%)]
F O ¼ {F5, F6} a(F4) 2 {normal, high}
FV ¼ {F3, F4} a(F5) {SC, OV}
a(F6) 2 {Yes, No}
Technical view: PP ¼ (B, MO, PR, CD, CS)
MO ¼ {m2, m6, m7, m8, m7.1, m7.2, m7.3}
m2: attri.fun ¼ transformer, b ¼ {1, 4}, e ¼ {4};
m6: attri.fun ¼ feedback, b ¼ {3}, e ¼ {5};
m6(i) 2 m6, i ¼ 1,2;
m7: attri.fun ¼ protection, b ¼ {3}, e ¼ {5};
m7(i) 2 m7, i ¼ 1,2,3;
m8: attri.fun ¼ start-up, b ¼ {1}, e ¼ {5};
m8(i) 2 m8, i ¼ 1,2;
m7.1: attri.fun ¼ SC, b ¼ {3}, e ¼ {7.3};
m7.2: attri.fun ¼ OV, b ¼ {3}, e ¼ {7.3};
m7.3: attri.fun ¼ compensation, b ¼ {3}, e ¼ {5}
PR ¼ {PR1, PR2, . . . , PR7}
PR1 ¼ (<A (M2, Nsec, f ), p), Nsec ¼ f [a(F3)],
p ¼ True, iff ja(F2)j 6¼ 12;
PR2 ¼ [<D (m6(1), m6(2), {3, 5}, {30, 50}, gl, gr, (3, 30), (5, 50)), p],
p ¼ True, iff a(F4) ¼ high;
PR3 ¼ [<G (m7, {3, 5}, {30, 50}, gl, gr, (3, 30), (5, 50)), p],
p ¼ True;
PR4 ¼ [<G (m7.1, {3, 7.3}, {30, 7.30}, gl, gr, (3, 30), (7.3, 7.30)), p],
p ¼ True, iff a(F5) 2 {{SC},{SC, OV}};
PR5 ¼ [<G (m7.2, {3, 7.3}, {30, 7.30}, gl, gr, (3, 30), (7.3, 7.30)), p],
p ¼ True, iff a(F5) 2 {{OV}, {SC, OV}};
PR6 ¼ [<D (m8(1), m8(2), {1, 5}, {10, 50}, gl, gr, (1, 10), (5, 50)), p],
p ¼ True, iff a(F5) 2 {{SC},{SC, OV}}.
Table 5. Algebraic description of the FB65-T platform.
platform is obtained. This coincides with the fact that one of the important instruments
of mass customization is to re-use previous knowledge. In such a situation, once rela-
tionships between customer requirements and technical design are identified, as long
as the design can be parsed, there is no need to follow the general design process to
construct the functional structure.
In addition, this research addresses the coordination of the customer and technical
views by designing the applicability of production rules, instead of by transformations
between graphs representing the functional and physical structures. This is because,
inherently, product features are non-structural. They are simply a list of customer
requirements, in which functional structures seldom exist. Furthermore, this research
uses the term ‘technical view’ rather than ‘structural view’, or ‘behaviour (physical)
view’. In practice, it is possible that the technical view means either the structure view
or the physical view, depending upon the characteristics of products and the design
strategy of the platform. For example, for electronics products, the technical view
Platform-based product configuration 165
involves nothing but resistances, capacitances, ICs, and so on. The working principle
of a product is determined by the connection of these components (i.e. the circuitry
topology of the product). Then, the product platform focuses on the structure view.
On the other hand, for mechanical products, the physical structure is much significant
for functionality. Then, the physical view becomes the focus of the platform.
It is also realized that most product platforms are much more complex than the exam-
ple presented in this research. Also, the application of graph grammars is far from being
well exploited. Future work is geared towards developing platform-based product
configuration systems. One promising application may be the integration of object-
oriented methods with graph grammars (Blostein et al. 1996, Jones 1995). Combining
advantages of encapsulation, inheritance, and polymorphism, the graph grammar-based
system will be more concise and powerful to deal with complex design problems.
7. Conclusions
Recognizing the rationale of platform-based product configuration with respect to
mass customization, this paper tackles the formal modelling issue of product platform.
The graph grammar approach excels in architectural modelling. Graph grammars
make explicit the structural elements of the platform, such as general product struc-
tures, common/shared elements, and variant derivation mechanisms. Complex
family-based product configuration can be modelled as graph transformations through
node nesting and executing productions, which facilitates computational approaches to
variety design. Graph grammars also provide a means to describe the design space of
product platform using graph languages.
Acknowledgements
This research was partially supported by Artesyn Technologies Asia–Pacific Ltd.
Under grant CPI 95/96.EG01, the HKUST Research Infrastructure Grant (RI 93/94
EG08), and the Hong Kong Research Grant Council (HKUST 797/96E and
HKUST 6220/99E). The authors would like to express their sincere thanks to
Dr M. Eugene Merchant, Prof. Stephen C.-Y. Lu, Num P. Suh, Gunnar Sohlenius
and Martin Helander for their valuable advice. One of the anonymous reviewers is
thanked for the insightful comments.
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