ROSEN: From 37 to 13 segments with a modular product architecture
A modular product architecture provides transparency regarding variants and makes it possible to assess opportunities for optimization. At ROSEN, a consistent product model was developed across all product variants for this purpose. This allowed for the systematic evaluation of module and variant structures, resulting in a reduction in the number of required segments from 37 to 13.
BEST PRACTICES in Mechanical Engineering: From 37 to 13 Segments—Through Transparent Product Architecture
Maximum Flexibility 🤖 :
With customized inline inspections, ROSEN detects metal loss, deformations, and other integrity risks—even under demanding conditions. The solutions are flexibly tailored to the specific pipeline challenge. The inspection robots used for this purpose are developed and manufactured to meet each customer’s specific needs.
Structured potential identified💡:
To be able to implement this wide range of variants more quickly and transparently in the future, ROSEN is actively driving the development of modular product systems. To this end, the team has
- A product model has been created that represents a consistent product structure across all product variants.
- Optimization Potential Identified Through a Structured Approach
- systematically prioritizes opportunities using complexity-based cost assessment.
Measurable Impact 📈:
Based on this, the team was able to directly evaluate the impact of concepts as well as variant and module structures—including in light of future market scenarios. As a result, the team succeeded in
- to reduce the number of segments required from 37 to 13 and, at the same time,
- to make the transition from an engineer-to-order approach to a configure-to-order approach.
Matthias Otten, Head of System Architecture Sensors at ROSEN, spoke about this transformation step at the Odego Industry Forum 2025: “The product model in Cquenz has enabled us to significantly reduce the number of segments, create transparency regarding the entire range of variants for all stakeholders, and at the same time lay a solid foundation for expanding to additional sizes.”
Keep up the good work, and thank you for the inspiring presentation and the exciting project!
The ROSEN example illustrates how a modular product architecture lays the foundation for systematic modularization. Variant and module structures are not designed in isolation, but are evaluated in terms of complexity, future market scenarios, and technical implications. This creates a robust foundation for scalable product structures and modular systems.
