Production of One

Flexible manufacturing is a production approach that allows factories to adapt to changes at speed — whether it's switching between different products, adjusting to supply chain disruptions or scaling production up or down. Instead of rigid, linear setups, flexible manufacturing relies on modular production lines, robotics integration, scenario simulations and real-time data integration to stay responsive and efficient.

A flexible production system is the key enabler of mass customization that allows factories to efficiently adapt production lines to demand fluctuations — here’s why:

• Supply chain resilience: Supports rapid adaptation to material shortages or disruptions, ensuring continuous delivery of customized products
• Shorter time to market: Facilitates faster transitions from design to production, helping companies meet customer expectations for quick delivery of custom goods
• Enhanced equipment efficiency: Manages resource allocation effectively by maximizing the use of assets and minimizing downtime between product variants
• Rapid product variation: Enables quick changeovers of production lines between different products or designs through machine flexibility to satisfy personalized customer demands
• Scenario simulation: Allows manufacturers to simulate production changes through the virtual twin before implementing them, reducing costly errors and speeding up reconfiguration

A flexible manufacturing process is powered by a combination of advanced technologies that make manufacturing more adaptive, resilient and customer-focused. Key technologies include the virtual twin which simulates and optimizes production digitally, modular and reconfigurable production lines that enable quick product switches and IIoT networks that connect equipment for real-time responsiveness. Besides that, AI and data analytics can predict shifts in demands and optimize operations, while robotics integration and automation provide speed and precision. Cloud collaboration tools and 3D configuration platforms also help manufacturers tailor products to individual customer needs without losing efficiency.

To manage lead time reduction while offering product personalization, manufacturers must adopt a digitally connected yet flexible manufacturing practices. Key approaches include:

• Using real-time supply chain insights and risk management tools to ensure you stay responsive to disruptions, avoiding shortage delays
• Implementing cloud-based collaboration and digital continuity to connect sales, engineering and production teams, accelerating product development
• Leveraging virtual twins to simulate and optimize production setups in advance, reducing time spent on trial-and-error in physical environments
• Adopting modular, reconfigurable production lines to switch between product variants without downtime or retooling delays swiftly
• Utilizing 3D selling experiences and configuration tools to help customers personalize products digitally and send that configuration data directly to manufacturing systems for efficient execution

Virtual twins support flexible manufacturing by providing a digital replica of production systems powered by real-time data, enabling simulation, testing and optimization without disrupting physical operations.

Powered by Dassault Systèmes’ 3DEXPERIENCE platform, manufacturers can leverage the virtual twin to adapt production lines to new products rapidly, demand fluctuations or sustainability goals. This helps reduce risk, accelerate market responsiveness and minimize waste, making flexible manufacturing more efficient, scalable and sustainable.

Traditional production lines are built for volume and repetition with a focus on linear mass production of standardized goods. However, they are often executed at the expense of flexibility and customization.

On the other hand, flexible manufacturing systems offers a smarter approach through cost-effective solutions — here’s how they deliver measurable value:

• Profitable production for small batch customization: With 3D selling platforms, personalized orders go straight into production without sacrificing efficiency
• Predictive maintenance and process automation: Virtual twins and real-time monitoring help identify and fix inefficiencies before they become costly
• Increased supply chain resilience: Enable rapid adaptation to disruptions with digitally connected systems that can shift sourcing and production strategies
• Enhanced market responsiveness to demand fluctuations: Integrated cloud collaboration tools allow sales, engineering and manufacturing to work in sync
• Minimized downtime and quick changeovers: Flexible production lines can be quickly reconfigured to handle different products, reducing downtime

Dassault Systèmes enables manufacturers to transition from rigid, traditional systems to highly agile and flexible manufacturing processes through the support of the 3DEXPERIENCE platform. This collaborative, cloud-based environment connects sales, engineering and operations teams to foster effective decision-making.

Powered by our platform, the virtual twin allows manufacturers to simulate, test and optimize production lines in a digital environment — reducing risks, development time and operational costs.

To further enhance flexibility, Dassault Systèmes supports the integration of 3D selling and configuration tools that capture customer needs through real-time data and feed them directly into the production workflow, enabling true mass customization with maximized efficiency.