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Product Platform

Area: Design, planning and building

 

Product platforms are a set of standardised components, processes, and knowledge used to create a variety of products and services. Borrowed from the software and manufacturing industries, this concept supports rapid innovation and growth by leveraging shared elements to achieve economies of scale and production flexibility (Lessing, 2006).  A product platform is closely related to the concept of solution space, highlighted by many authors as being one of the fundamental capabilities to implement mass customisation strategies (Salvador et al., 2009). A solution space refers to the range of potential designs or configurations that can be generated within the constraints of a given product platform. It encompasses all the possible variations and customisations that can be achieved using the standardised components and processes defined by the platform (Piller, 2004). Therefore, the product platform provides the kit-of-parts, production processes and knowledge, while the solution space defines the extent to which those elements can be varied to meet specific needs and preferences.

Product platforms are central to the development of customised and industrialised housing solutions. By sharing standardised components across various housing products, companies can achieve significant cost reductions while allowing for customisation to meet specific market demands. This balance enhances the ability to provide affordable and tailored housing without sacrificing quality or functionality. Other industries, such as automotive and electronics, have demonstrated the efficiency benefits of product platforms by streamlining production processes, reducing costs, and quickly adapting to market changes. Adopting a similar approach in housing can accelerate innovation and reduce overall costs in the construction sector.

Product platforms provide a structure for predefined technical solutions, requiring thorough documentation and continuous improvements, and serving as a backbone for technical information and related processes in a company and its supply chain (Jansson et al., 2014). Robertson and Ulrich (1998) identified four elements that constitute a product platform: components, processes, knowledge, people and relationships. These platforms must integrate common elements and technologies across a range of products, considering manufacturing capabilities and constraints early in the process. This integration ensures that the product platform is not only flexible in the early definition of a housing solution but is also practical and efficient to produce.

Flexibility is both key to the success of a product platform in housing and a challenge for scaling manufacturing. It is crucial to find the right balance between standardisation and customisation to meet customer demands efficiently. Therefore, it is vital to integrate customer focus in product-oriented house-building processes (Barlow et al., 2003) and to define the Customer Order Decoupling Point (CODP) in the production process – the point in which the product will be customised to meet specific needs. The CODP determines the production strategy of a product platform, which will consequently affect its inventory management, lead times, and overall supply chain strategy. The production strategy defines the boundaries and degrees of customisation within a product platform, classified into four levels: Made-to-Stock (MTS), Assembled-to-Stock (ATS), Made-to-Order (MTO) or Engineered-to-Order (ETO) (Barlow, 1998; Smith, 2019).

Product platforms allow us to understand a building in a systematic way, as a group of components or smaller subsystems that can be designed independently yet function together as a whole. This approach enables continuous improvement of the platform, as insights from one project can drive more efficient use of components in subsequent projects, creating learning loops that enhance overall productivity and innovation. Additionally, a product platform developed with Design for Manufacture and Assembly (DfMA) and Design for Disassembly (DfD) principles can significantly contribute to a circular economy. Standardised components can be easily repurposed or reconfigured, reducing waste and promoting environmental sustainability. This flexibility ensures that buildings can adapt to changing needs over time, extending their lifespan and minimising the environmental impact of demolition and new construction.

Finally, there are four principles that should be considered when developing product platforms for the delivery of housing:

(1) Modularity:  Product modularity enables a manufacturer to absorb changes in customer needs by reconfiguring and adapting modules based on a set of parameters within a defined solution space. 

(2) Automation: Integrating digital workflows to automate repetitive tasks such as manufacturing instructions, building reports or a bill of quantities would ease the development of a variety of housing solutions in an efficient way.

(3) Platform rules: The rules and relationships between platform components would have to be properly defined to ensure that consistency in quality and performance are maintained even when designs are customised or scaled.

(4) Parametric software tools: The success of a product platform relies on how data generated in the manufacturing and assembly phases is encapsulated within the components and incorporated into the early stages and project planning. Parametric software can facilitate the iteration of options without leaving the product platform’s solution space, optimising the design based on performance data, environmental parameters, or user feedback.

References

Barlow, J. (1998). From Craft Production To Mass Customization? Customer-Focused Approaches To House Building. International Group of Lean Construction.

Barlow, J., Childerhouse, P., Gann, D., Hong-Minh, S., Naim, M., & Ozaki, R. (2003). Choice and delivery in housebuilding: Lessons from Japan for UK housebuilders. Building Research and Information, 31(2). https://doi.org/10.1080/09613210302003

Jansson, G., Johnsson, H., & Engström, D. (2014). Platform use in systems building. Construction Management and Economics, 32(1–2). https://doi.org/10.1080/01446193.2013.793376

Lessing, J. (2006). Industrialised house-building: Concept and Processes. In Lic. Thesis.

Piller, F. (2004). Mass customization: Reflections on the state of the concept. International Journal of Flexible Manufacturing Systems, 16(4 SPEC. ISS.). https://doi.org/10.1007/s10696-005-5170-x

Robertson, D., & Ulrich, K. (1998). Planning for Product Platforms. Sloan Management Review, 39(4).

Salvador, F., Martin de Holan, P., & Piller, F. (2009). Cracking the Code of Mass Customization. MIT Sloan Management Review, 50(3).

Smith, R. E. (2019). Mass Prefabrication: Investigating the Relationship Between Prefabrication And Mass Customization in Architecture. In Mass Customization and Design Democratization. https://doi.org/10.4324/9781351117869-14

Created on 19-06-2024 | Update on 23-10-2024

Related definitions

Mass Customisation

Author: C.Martín (ESR14)

Area: Design, planning and building

Mass customisation (MC) is a process by which a company approaches its production in a customer-centric manner, developing products and services according to the needs and requirements of each individual customer, while keeping costs near to mass production (Piller, 2004). MC establishes a new relationship between producers and customers which becomes crucial in product development  (Khalili-Araghi & Kolarevic, 2016). Alvin Toffler (1970, 1980) was the first to refer to the MC concept in his books “Future shock”  and “The third wave”. Stanley Davis (1987) later cemented the term in his book “Future Perfect”. But it was not until 1993, when Joseph Pine  developed its practical application to business, that the concept started gaining greater importance in research and practice (Pine, 1993; Brandão et al., 2017; Piller et al., 2005). Nowadays, MC is understood as a multidimensional process embracing a combination of mass production, user-driven technologies, big data, e-commerce and e-business, digital design, and manufacturing technologies (Brandão et al., 2017). In the last twenty years, almost every sector of the economy, from industrial production to consumer products and services, has been influenced by mass customisation. The difference between mass customisation and massive customisation is the ability to relate the contextual features to the product features. This means that a random generation of design alternatives would not be sufficient; these alternatives should be derived from the cultural, technological, environmental and social context, as well as from the individual context of the user (Kolarevic & Duarte, 2019). As a business paradigm,  MC provides an attractive added value by addressing customer needs while using resources efficiently and avoiding an increase in operational costs (Piller & Tseng, 2009). It seeks to incorporate customer co-design processes into the innovation and strategic planning of the business, approaching economies of integration (Piller et al., 2005). As a result, the profitability of MC is achieved through product variety in volume-related economies (Baranauskas et al., 2020; Duray et al., 2000). The space in which it is possible to meet a variety of needs through a mass customisation offering is finite (Piller, 2004). This solution space represents the variety of different customisation units and encompasses the rules to combine them, limiting the set of possibilities in the search of a balance between productivity and flexibility (Salvador et al., 2009). The designer’s responsibility would be to meet the heterogeneities of the users in an efficient way, by setting a solution space and defining the degrees of freedom for the customer within a manufacturer’s production system (Hippel, 2001). Therefore, an important challenge for a company that aims at becoming a mass customizer is to find the right balance between what is determined by the designer and what is left for the user to decide (Kolarevic & Duarte, 2019). Value creation within a stable solution space is one of the major differences between traditional customisation. While a traditional customizer produces unique products and processes, a mass customizer uses stable processes to provide a high range of variety among their products and services (Pine, 1993). This would enable a mass customizer to achieve “near mass production efficiency” but would also mean that the customisation alternatives are limited to certain product features (Pine, 1995). As opposed to the industrial output of mass production, in which the customer selects from options produced by the industry, MC facilitates cultural production, the personalisation of mass products in accordance with individual beliefs. This means that the customer contributes to defining the processes, components, and features that will be involved in the flow of the design and manufacturing process (Kieran & Timberlake, 2004). Products or services that are co-designed by the customer may provide social benefits, resulting in tailor-made, fitting, and resilient outcomes (Piller et al., 2005). Thanks to parametric design and digital fabrication it is now viable to mass-produce non-standard, custom-made products, from tableware and shoes to furniture and building components. These are often customizable through interactive websites (Kolarevic & Duarte, 2019). The incorporation of MC into the housebuilding industry, through supporting, guiding, and informing the user via interactive interfaces (Madrazo et al., 2010), can contribute to a democratisation of housing design, allowing for an empowering, social, and cultural enrichment of our built environment. Our current housing stock is largely homogeneous, while customer demands are increasingly heterogeneous. Implementing MC in the housing industry could address the diverse consumer needs in an affordable and effective way, by creating stable solution spaces that could make good quality housing accessible to more dwellers. Stability and responsiveness are key in the production of highly customised housing. Stability can be achieved through product modularity, defining and producing a set of components that can be combined in the maximum possible ways, attaining responsiveness to different requests while reducing the complexity of product variation. This creates customisation alternatives within the solution space which require a smooth flow of information and effective collaboration between customers, designers, and manufacturers (Khalili-Araghi & Kolarevic, 2018). ICT technologies can help to effectively materialise this multidimensional and interdisciplinary challenge in the Architecture, Engineering and Construction (AEC) industry, as showcased in the Sato PlusHome multifamily block in Finland[1]. Nowadays, there are companies that have integrated a systematic methodology to produce mass customised single-family homes using prefabrication methods, such as Modern Modular[2]. On the other hand, platforms such as BIM that act as collaborative environments for all stakeholders have demonstrated that building performance can be increased and precision improved while reducing construction time. These digital twins offer a basis for fabricated components and enable early cooperation between different disciplines. Parametric tools have the potential to help customisation comply with the manufacturing rules and regulations, and increase the ability to sustainably meet customer requirements, using fewer resources and shorter lead times (Piroozfar et al., 2019). In summary, a mass customisable housing industry could be achieved if the products and services are parametrically defined (i.e., specifying the dimensions, constraints, and relationships between the various components), interactively designed (via a website or an app), digitally fabricated, visualised and evaluated to automatically generate production and assembly data (Kolarevic, 2015). However, for MC to be integrated effectively in the AEC industry, several challenges remain that range from cultural, behavioural and management changes, to technological such as the use of ICTs or those directly applied to the manufacturing process, as for example automating the production and assembly methods, the use of product configurators or managing the variety through the product supply chain (Piroozfar et al., 2019).   [1] Sato PlusHome. ArkOpen / Esko Kahri, Petri Viita and Juhani Väisänen (http://www.open-building.org/conference2011/Project_PlusHome.pdf) [2] The Modern Modular. Resolution: 4 Architecture (https://www.re4a.com/the-modern-modular)

Created on 06-07-2022 | Update on 23-10-2024

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Housing Affordability

Author: A.Elghandour (ESR4), K.Hadjri (Supervisor)

Area: Design, planning and building

Housing can be perceived as consisting of two inseparable components: the product and the process. The product refers to the building as a physical artefact, and the process encompasses the activities required to create and manage this artefact in the long term (Turner, 1972), as cited in (Brysch & Czischke, 2021). Affordability is understood as the capability to purchase and maintain something long-term while remaining convenient for the beneficiary's resources and needs (Bogdon & Can, 1997). Housing Affordability is commonly explained as the ratio between rent and household income (Hulchanski, 1995). However, Stone (2006, p.2) proposed a broader definition of housing affordability to associate it with households' social experience and financial stability as: "An expression of the social and material experiences of people, constituted as households, in relation to their individual housing situations", ….. "Affordability expresses the challenge each household faces in balancing the cost of its actual or potential housing, on the one hand, and its non-housing expenditures, on the other, within the constraints of its income." Housing costs signify initial and periodic payments such as rent or mortgages in the case of  homeowners, housing insurance, housing taxes, and so on. On the other hand, non-housing costs include utility charges resulting from household usage, such as energy and water, as well as schools, health, and transportation (AHC, 2019; Ezennia & Hoskara, 2019). Therefore, housing affordability needs to reflect the household's capability to balance current and future costs to afford a house while maintaining other basic expenses without experiencing any financial hardship (Ezennia & Hoskara, 2019). Two close terminologies to housing affordability are  “affordable housing” and “affordability of housing”. Affordable housing is frequently mentioned in government support schemes to refer to the housing crisis and associated financial hardship. In England, affordable housing is still concerned with its financial attainability, as stated in the UK Government's official glossaries: "Housing for sale or rent, for those whose needs are not met by the market (including housing that provides a subsidised route to home ownership and/or is for essential local workers)", while also complying with other themes that maintain the affordability of housing prices in terms of rent or homeownership (Department for Levelling Up Housing and Communities, 2019). The affordability of housing, on the other hand, refers to a broader focus on the affordability of the entire housing market, whereas housing affordability specifically refers to the ability of individuals or households to afford housing. In the literature, however, the term “affordability of housing” is frequently used interchangeably with “housing affordability,” despite their differences (Robinson et al., 2006). The "affordability of housing" concerns housing as a sector in a particular region, market or residential area. It can correlate affordability with population satisfaction, accommodation types and household compositions to alert local authorities of issues such as homelessness (Kneebone & Wilkins, 2016; Emma Mulliner et al., 2013; OECD, 2021). That is why the OECD defined it as "the capacity of a country to deliver good quality housing at an accessible price for all" (OECD, n.d.). Short-term and long-term affordability are two concepts for policymakers to perceive housing affordability holistically. Short-term affordability is "concerned with financial access to a dwelling based on out-of-pocket expenses", and long-term affordability is " about the costs attributed to housing consumption" (Haffner & Heylen, 2011, p.607). The costs of housing consumption, also known as user costs, do not pertain to the monthly utility bills paid by users, but rather to the cost associated with consuming the dwelling as a housing service  (Haffner & Heylen, 2011). “Housing quality” and “housing sustainability” are crucial aspects of housing affordability, broadening its scope beyond the narrow economic perspective within the housing sector. Housing affordability needs to consider "a standard for housing quality" and "a standard of reasonableness for the price of housing consumption in relation to income" (p. 609) (Haffner & Heylen, 2011). In addition, housing affordability requires an inclusive aggregation and a transdisciplinary perspective of sustainability concerning its economic, social, and environmental facets (Ezennia & Hoskara, 2019; Perera, 2017; Salama, 2011). Shared concerns extend across the domains of housing quality, sustainability, and affordability, exhibiting intricate interrelations among them that require examination. For instance, housing quality encompasses three levels of consideration: (1) the dwelling itself as a physically built environment, (2) the household attitudes and behaviours, and (3) the surroundings, encompassing the community, neighbourhood, region, nation, and extending to global circumstances (Keall et al., 2010). On the other hand, housing sustainability embraces the triad of economic, social, and environmental aspects. The shared problems among the three domains encompass critical aspects such as health and wellbeing, fuel poverty and costly long-term maintenance  proximity to workplaces and amenities, as well as the impact of climate. Health and wellbeing Inequalities in health and wellbeing pose a significant risk to social sustainability, mainly in conditions where affordable dwellings are of poor quality. In contrast, such conditions extend the affordability problem posing increased risks to poor households harming their health, wellbeing and productivity (Garnham et al., 2022; Hick et al., 2022; Leviten-Reid et al., 2020). An illustrative example emerged during the COVID-19 pandemic, where individuals residing in unsafe and poor-quality houses faced higher rates of virus transmission and mortality (Housing Europe, 2021; OECD, 2020). Hence, addressing housing affordability necessitates recognising it as a mutually dependent relationship between housing quality and individuals (Stone, 2006). Fuel poverty and costly long-term maintenance Affordable houses of poor quality pose risks of fuel poverty and costly long-term maintenance. This risk makes them economically unsustainable. For example, good quality entails the home being energy efficient to mitigate fuel poverty. However, it might become unaffordable to heat the dwelling after paying housing costs because of its poor quality (Stone et al., 2011). Thus, affordability needs to consider potential fluctuations in non-housing prices, such as energy bills (AHC, 2019; Smith, 2007). Poor quality also can emerge from decisions made during the design and construction stages. For example, housing providers may prioritise reducing construction costs by using low-quality and less expensive materials or equipment that may lead to costly recurring maintenance and running costs over time (Emekci, 2021). Proximity to work and amenities The proximity to workplaces and amenities influences housing quality and has an impact on economic and environmental sustainability. From a financial perspective, Disney (2006) defines affordable housing as "an adequate basic standard that provides reasonable access to work opportunities and community services, and that is available at a cost which does not cause substantial hardship to the occupants". Relocating to deprived areas far from work opportunities, essential amenities, and community services will not make housing affordable (Leviten-Reid et al., 2020). Commuting to a distant workplace also incurs environmental costs. Research shows that reduced commuting significantly decreases gas emissions (Sutton-Parker, 2021). Therefore, ensuring involves careful planning when selecting housing locations, considering their impact on economic and environmental sustainability (EK Mulliner & Maliene, 2012). Moreover, design practices can contribute by providing adaptability and flexibility, enabling dwellers to work from home and generate income (Shehayeb & Kellett, 2011). Climate change's mutual impact Climate change can pose risks to housing affordability and, conversely, housing affordability can impact climate change. A house cannot be considered "affordable" if its construction and operation result in adverse environmental impacts contributing to increased CO2 emissions or climate change (Haidar & Bahammam, 2021; Salama, 2011). For a house to be environmentally sustainable, it must be low-carbon, energy-efficient, water-efficient, and climate-resilient (Holmes et al., 2019). This entails adopting strategies such as incorporating eco-friendly materials, utilizing renewable energy sources, improving energy efficiency, and implementing sustainable water management systems (Petrović et al., 2021). However, implementing these measures requires funding initiatives to support the upfront costs, leading to long-term household savings (Holmes et al., 2019). Principio del formulario Furthermore,  when houses lack quality and climate resilience, they become unaffordable. Households bear high energy costs, especially during extreme weather conditions such as heatwaves or cold spells (Holmes et al., 2019). Issues like cold homes and fuel poverty in the UK contribute to excess winter deaths (Lee et al., 2022). In this context, climate change can adversely affect families, impacting their financial well-being and health, thereby exacerbating housing affordability challenges beyond mere rent-to-income ratios.    

Created on 17-10-2023 | Update on 23-10-2024

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Design for Disassembly

Author: A.Davis (ESR1)

Area: Design, planning and building

Design for Disassembly (DfD), also referred to as Design for Deconstruction or Construction in Reverse, is the design and planning of the future disassembly of a building, in addition to its assembly (Cruz Rios & Grau, 2019). Disassembly enables the non-destructive recovery of building materials to re-introduce resources back into the supply chain, either for the same function or as a new product. Designing buildings for their future disassembly can reduce both the consumption of new raw materials and the negative environmental impacts associated with the production of new building products, such as embodied carbon. DfD is considered the “ultimate cradle-to-cradle cycle strategy” (Smith, 2010, p.222) that has the potential to maximise the economic value of materials whilst minimising harmful environmental impacts. It is therefore a crucial technical design consideration that supports the transition to a Circular Economy. Additional benefits include increased flexibility and adaptability, optimised maintenance, and retention of heritage (Rios et al., 2015). DfD is based on design principles such as: standardised and interchangeable components and connections, use of non-composite products, dry construction methods, use of prefabrication, mechanical connections as opposed to glues and wet sealants, designing with safety and accessibility in mind, and documentation of materials and methods for disassembly (Crowther, 2005; Guy & Ciarimboli, 2008; Tingley & Davison, 2011). DfD shares commonality with Industrialised Construction, which often centres around off-site prefabrication. Industrialising the production of housing can therefore be more environmentally sustainable and financially attractive if building parts are produced at scale and pre-designed to be taken apart without destroying connecting parts. Disassembly plays an important role in the recovery of building materials based on the 3Rs principle (reduce, reuse, recycle) during the maintenance, renovation, relocation and reassembly, and the end-of-life phases of a building. Whilst a building is in use, different elements are expected to be replaced at the end of their service life, which varies depending on its function. For example, the internal layout of a building changes at a different rate to the building services, and the disassembly of these parts would therefore take place at different points in time. Brand’s (1994) Shearing Layers concept incorporates this time aspect by breaking down a building into six layers, separating the “site”, “structure”, “skin” (building envelope), “services”, “space plan”, and “stuff” (furniture) to account for their varying lifespans. DfD enables the removal, replacement, and reuse of materials throughout the service life of a building, extending it use phase for as long as possible. However, there is less guarantee that a building will be disassembled at the end of its service life, rather than destructively demolished and sent to landfill.

Created on 18-10-2023 | Update on 23-10-2024

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Industrialised Construction

Author: C.Martín (ESR14), A.Davis (ESR1)

Area: Design, planning and building

Industrialised Construction, also referred to as Modern Methods of Construction in the UK (Ministry of Housing, 2019) and Conceptueel Bouwen (Conceptual Building) in the Netherlands (NCB, n.d.), is a broad and dynamic term encompassing innovative techniques and processes that are transforming the construction industry (Lessing, 2006; Smith & Quale, 2017). It is a product-based approach that reinforces continuous improvement, rather than a project-based one, and emphasises the use of standardised components and systems to improve build quality and achieve sustainability goals (Kieran & Timberlake, 2004).  Industrialised Construction can be based on using a kit-of parts and is often likened to a LEGO set, as well as the automotive industry's assembly line and lean production. Industrialisation in the construction sector presents a paradigm shift, driven by advancements in technology (Bock & Linner, 2015). It involves both off-site and on-site processes, with a significant portion occurring in factory-controlled conditions (Andersson & Lessing, 2017). Off-site construction entails the prefabrication of building components manufactured using a combination of two-dimensional (2D), three-dimensional (3D), and hybrid methods, where traditional construction techniques meet cutting-edge technologies such as robotic automation. Industrialised construction is not limited to off-site production, it also encompasses on-site production, including the emerging use of 3D printing or the deployment of temporary or mobile factories. Industrialised Construction increasingly leverages digital and industry 4.0 technologies, such as Building Information Modelling (BIM), Internet of Things, big data, and predictive analysis (Qi et al., 2021). These processes and digital tools enable accurate planning, simulation, and optimisation of construction processes, resulting in enhanced productivity, quality, and resource management. It is important to stress that Industrialised Construction is not only about the physical construction methods, but also the intangible processes involved in the design and delivery of buildings. Industrialised construction offers several benefits across economic, social, and environmental dimensions. From an economic perspective, it reduces construction time and costs in comparison to traditional methods, while providing safer working conditions and eliminates delays due to adverse weather. By employing standardisation and efficient manufacturing processes, it enables affordable and social housing projects to be delivered in a shorter timeframe through economies of scale (Frandsen, 2017). On the social front, Industrialised Construction can enable mass customisation and customer-centric approaches, to provide more flexible solutions while maintaining economic feasibility (Piller, 2004). From an environmental standpoint, industrialised construction minimises waste generation during production by optimising material usage and facilitates the incorporation of Design for Disassembly (Crowther, 2005) and the potential reusability of building elements, promoting both flexibility and a Circular Economy (EC, 2020). This capability aligns with the principles of cradle-to-cradle design, wherein materials and components are continuously repurposed to reduce resource depletion and waste accumulation. Challenges remain in terms of overcoming misconceptions and gaining social acceptance, the slow digital transformation of the construction industry, high factory set-up costs, the lack of interdisciplinary integration of stakeholders from the initial stages, and adapting to unconventional workflows. However, Industrialised Construction will undoubtedly shape the future of the built environment, providing solutions for the increasing demand for sustainable and affordable housing (Bertram et al., 2019).

Created on 09-11-2023 | Update on 23-10-2024

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