Reconfigurable production system design - theoretical and practical challenges

Purpose - The purpose of this paper is to explore theoretical and practical challenges to achieve reconfigurable production system designs. Design/methodology/approach - The empirical material of this paper includes a multiple-case study with an embedded design (Yin) including four cases, where each case represents a production system design project. The consideration of reconfigurability and its characteristics in the production system design projects was studied. To enhance validity, two real-time studies were combined with two retrospective studies (Leonard-Barton). Findings - For more than a decade foresight reports have pointed out the need for responsiveness to change through reconfigurability in production system design. In order to achieve reconfigurable production systems, three challenges were identified: to use a structured design methodology, to gain knowledge in reconfigurability and its characteristics, and to include the reconfigurability knowledge in a structured design methodology. Still there is no comprehensive support available for reconfigurability in the production system design process. Research limitations/implications - Limitations are mostly related to the chosen methodology approach, and additional empirical studies to establish generic results are required. Practical implications - By combining knowledge from the production system design field with the reconfigurable manufacturing system field a potential of meeting identified challenges is pointed out. Originality/value - This paper adds to current knowledge by pointing out three main challenges to achieving reconfigurable production systems. The paper also contributes with ideas on how to respond to these challenges.