Synchronisation of material flows in mass-customised production systems: a literature-based classification framework and industrial application

The mass customisation strategy is needed by manufacturing companies to face the increasing variety and unpredictability of products required by customers. However, mass customisation may increase the complexity of managing manufacturing and production logistics activities, for example due to reduced product batch sizes. The synchronisation of material flows within the factory is emerging as a way to address this complexity, as it enables an effective and efficient implementation of mass customisation. Indeed, the fourth Industrial Revolution introduces new digital levers, which can be combined with traditional managerial levers to achieve the synchronisation of material flows within the factory. This study contributes to the rising stream of research on this topic. A systematic literature review was conducted, leading to the development of a classification framework of the levers supporting the synchronisation of material flows. The identified managerial levers are: storage of materials, feeding policy, and scheduling. The digital levers are: materials tracking, process tracking, data analytics, and assistance systems. The developed framework was operationalised in four industrial cases and applied as a tool to map their levers related to the synchronisation of material flows.