Mass customization (MC) manufacturing requires high flexibility to respond to customer needs in a timely manner. Lean manufacturing
principles can be easily applied to situations with low levels of MC. However, as the degree of customization increases and
customer involvement occurs earlier in the design and fabrication stages, the direct application of lean principles to maintain
flow and low levels of inventory becomes difficult. This paper presents a framework to show how other strategies such as Quick
Response manufacturing/POLCA, Theory of Constraints, Flexible/Reconfigurable Manufacturing Systems, etc. can be integrated
with lean in MC environments. A case study of boat mass customizer is then used to demonstrate how their operations are transformed
by for more efficient MC. Simulation models are used to compare pre- and post-improvement performance.
Keywords Mass customization – Make-to-order manufacturing – Lean manufacturing – Pull – Kanban – CONWIP