Controlling variety-induced complexity in mass customisation: a key metrics-based approach

Due to the multitude of customer needs, mass customisation induces extensive product variety, which is associated with high complexity in operations and manufacturing-related tasks. Variety-induced complexity is one of the most important problems that can lead mass customisation to failure. Due to several drawbacks of existing methods in coping with complexity, we propose a key metrics-based approach. After determining the main subprocesses that are necessary to make mass customisation work efficiently, we assign to each subprocess the key metrics that can capture the variety-induced complexity. However, single key metrics have a limited informational value. Therefore, we integrate them into a comprehensive system that illustrates the correlations existing between the identified measures. The elaborated system enables one to detect the levers that should be considered in order to keep variety-induced complexity under control.