Abstract

A product family built on a modular architecture has the advantage of efficiently expanding its product range through selective differentiation of modules while reusing others. However, the purposes and capabilities of existing module variants are often unclear, making their reuse difficult and leading to unnecessary creation of additional variants. This study introduces Variant Mode and Effects Analysis (VMEA), a structured framework for module differentiation that discloses key variant characteristics such as the mode, cause, and impact of differentiation. The framework provides a step-by-step process for capturing these characteristics and a documentation scheme for their records. We demonstrated the effectiveness of the framework through a case study of an automotive suspension system. The accumulated records of the module variants serve as a catalogue for reuse, enhancing their reusability. Furthermore, it offers valuable insight into architectural reforms by identifying compatibility bottlenecks and historical differentiation patterns.