By Astrid Helene Mortensen, AAU Communication and Public Affairs

In a world where efficiency, flexibility, and adaptability are crucial for ensuring the success of companies, the REKON project offers a groundbreaking approach to modular production that not only transforms the way we think about production but also ensures the long-term resilience and competitiveness of Danish companies.

The project is a collaboration between Aalborg University, the Danish Technological Institute, the University of Southern Denmark, and Jönköping University. The project has created new opportunities for Danish companies to optimize their production systems and strengthen their resilience in a rapidly changing global economy.

Modular production as the solution of the future
As markets grow more dynamic and product life cycles continue to shorten, the capacity for rapid adaptation has emerged as a decisive competitive advantage.

The REKON project has therefore focused on developing production systems in which equipment, processes, and components are modular—designed to be easily replaced or reconfigured as needed. This approach enables companies to reduce investment costs, enhance flexibility, and better keep pace with evolving technological and market demands.

The project received a grant of 8.18 million DKK from the Industry Foundation and spanned the period from February 2020 to March 2023. During this time, seven pilot companies participated, including Volvo, Vestas, Elvstrøm Sails, Grundfos, and Kamstrup. These companies had the opportunity to test and develop modular production solutions, which were then shared with up to 75 other Danish companies.

Building a Greener Future: Volvo’s Modular Production Approach
Volvo GTO is an example of how modular production can support an ambitious green transition. The company has set a goal that by 2040, all new trucks leaving its factories will run on electricity or green fuels. This requires a comprehensive transformation of the production system, and with help from the REKON project, Volvo has gained a better understanding of how to create greater flexibility in its production.

Rather than making large up-front investments, Volvo has adopted a new approach: designing its production equipment using a modular architecture. This means that systems, equipment, and processes are built from interchangeable modules that can be easily adapted or upgraded as needed. As a result, investments can be distributed over time, explains Tobias Högfeldt, Production Engineer and Global Operations Manager for Production at Volvo GTO Powertrain.

“This means we can increase volume and capacity by adding more modules, and it also means smaller investments at a time. Demand will rise over time, but we want to avoid making all the major investments upfront.”

Sailing Ahead: Elvstrøm’s Smart Use of Data
For Elvstrøm Sails, the transition isn’t just about modular production - it’s also about leveraging data to optimize production processes. Through their participation in the REKON project, Elvstrøm has applied machine learning to analyze four years of production data and develop a prioritization system that ensures production is always focused on the most urgent tasks.

“We’ve crunched tons of data, distilled the essence, and categorized the sails into 40 base types. We’ve primarily extracted data on time usage across various processes and employees, and when we combine that with a prioritization system, we get a ranked list that tells us which sail to produce first,” explains Supply Chain Director Finn Mortensen.

This has enabled the company to reduce delivery times from four to three weeks, giving them a significant competitive edge in the global sailboat market.

“We’re number two in the world at what we do, but we’re working to close in on number one by being the fastest to deliver,” says Finn Mortensen.

Spreading Knowledge and Methods to More Companies
The positive results from the seven pilot companies involved in the REKON project have already had a broader impact. Knowledge, methods, and tools from the project have been shared with 75 companies, which have now implemented the same flexible and efficient production systems. This has not only strengthened their competitiveness in the global market but also made them better equipped to meet future demands and uncertainties.

Ann-Louise Andersen, Associate Professor at the Department of Materials and Production at Aalborg University, explains that the greatest advantage of modular production is its ability to help companies quickly adapt to new market demands and technologies.

“It’s a strategic advantage for companies needing to respond to unpredictable market needs,” she says, emphasizing that modularization can lead to significant savings in development time, equipment investments, and other costs.

The REKON Project Paves the Way for Denmark’s Industrial Future
In close collaboration between research and industry, new advanced production methods are being developed to secure Denmark’s competitiveness in a green and sustainable economy. REKON provides companies with the foundation they need to take the lead - both globally and in the green transition.

The REKON project is the driving force behind a new industrial standard - where flexibility, adaptability, and competitiveness go hand in hand.