Modularity-based innovation strategy for the development of nautical products: case study on competitiveness and operational efficiency

Abstract

Abstract The nautical industry faces significant challenges in the development of serial products, requiring management methods adapted to the Product Development Process (PDP). Currently, practices are largely inherited from heavy shipbuilding, where a spiral logic of development prevails. This article aims to propose, apply, and evaluate a sequential framework specific to the sport and recreational boat sector that incorporates modularity into PDP, an approach that is still uncommon in the nautical industry but has already proven beneficial in other manufacturing domains. The study focuses on sport and leisure vessels between 30 and 40 feet in length, manufactured from composite materials such as resins and fiberglass. The research employs a qualitative approach through a single case study at a medium-sized Brazilian shipyard, with data collection based on direct observation of the manufacturing environment and document analysis of technical reports, schedules, and operational-economic indicators. As a complementary step, a systematic review aligned with PRISMA 2020 guidelines was conducted. The implementation of the framework yielded substantial gains: a reduction in the return on investment period from approximately 4 years to 2 years, an 86% reduction in raw material costs for mold manufacturing, and significant environmental improvements from reduced resource consumption and component reuse. Beyond the economic and environmental advantages, modularity also enhanced process quality by fostering a more critical and systematic assessment of management, design, and engineering decisions throughout product development.