Barriers to Adopting Design for Assembly in Modular Product Architecture: Development of a Conceptual Model Through Content Analysis

Abstract: This study investigates the barriers to integrating Design for Assembly (DFA) principles within modular product architectures established using the Modular Function Deployment (MFD) method -- a critical stage for deploying mass customization production while reducing costs. Despite the potential benefits of DFA, its application in modular architectures development remains underutilized, due to a mix of challenges. Through content analysis of qualitative data gathered from a focus group and interviews with industry experts and practitioners, we identified four major categories of such challenges, or barriers to adoption of DFA: technological, economic, regulatory, and organizational (TERO). Key challenges include compliance with regulatory requirements for data usage, intellectual property concerns, and limited availability of quantitative data in the initial stages of MFD. The findings reveal that multidisciplinary collaboration is essential to addressing these barriers, as it enhances informed decision making and eases the practical integration of DFA. By analyzing insights from both academic literature and industrial practice, this research develops a conceptual model that describes the main issues of applying DFA in MFD, providing a valuable guide for companies aiming to improve their modular products assembly process. Ultimately, this study provides groundwork to support industry practitioners in overcoming existing barriers, promoting more cost effective, high quality modular design processes with the inclusion of efficient assembly considerations.