Integrating design for assembly in modular product architecture: barriers, insights, and a framework for early-stage guidance

This study examines barriers to integrating design for assembly (DFA) principles into modular product architectures using the modular function deployment (MFD) method–a critical step for enabling cost-efficient mass customisation. Despite the known benefits of DFA, its adoption in early design stages remains limited. Drawing on qualitative insights from a focus group involving industry practitioners and advanced engineering students, as well as a prior systematic literature review, the study identifies key challenges. Results are classified into primary–closely aligned with research gaps–and secondary themes, emerging during practice-based discussions. These findings are synthesised into a conceptual framework structured around technological, economic, regulatory, and organisational (TERO) barriers. The framework provides guidance for integrating DFA earlier in modularisation, supporting more efficient, adaptable, and high-quality designs. It also outlines actionable areas for future research, including early-stage evaluation methods, AI-augmented design practices, and strategies for structuring knowledge repositories and promoting cross-functional collaboration.