The rapid development of new technologies such as electrification, autonomy, and other contextual factors pose significant challenges to development teams in balancing competing aspects while developing value-robust solutions. One approach for achieving value robustness is designing for changeability. This paper presents a tradespace exploration from a Systems-of-Systems perspective to facilitate changeability assessment during early design stages. The approach is further demonstrated on a fleet of haulers operating in a mining site.

In 3D printing, calibration is crucial for accurate prints, particularly those with complex or intricate features. This paper focuses on developing, manufacturing, and testing a benchmarking model to assess the dimensional accuracy of 3D printers. The aim is to evaluate the 3D printed model against a universally recognized real-world equivalent – a LEGO® brick – using its interlock function as a test with an engaging element. An interlock benchmarking framework aids further analysis of the model's performance, and a checklist for the model is provided for additional visual analysis.

In the field of 3D model reconstruction, manifold methods have been developed that derive CAD models from 3D scan data. Opposed to classical CAD modelling, where surface and solid modelling exist, a further diversification of modelling techniques is observed, caused by different methods to build up the geometry. This research introduces a new classification, the so-called Level of Complexities. It can be applied to the complete Reverse Engineering process chain and lays the foundation for further research on how to match requirements arising from all process steps and downstream applications.

Prior research has shown the importance of latent user needs for enabling innovation in early product development phases. The success of a product is largely dependent on to what extent the product satisfies customer needs, and latent user needs play a significant role in impacting the way the product or service unexpectedly delights the user. Complications arise because traditional need finding methods are not able to account for the nuances of latent user needs. A user's need is multidimensional while traditional methods are built on deductive reasoning. The traditional method isolates parts of the user's needs, only pointing to what is deducible within its search space. To address this, we introduce abduction as a way to broaden traditional need finding methods. From a logic based argument it is shown that abduction accounts for the dimensionality of user needs by integrating various traditional need finding theories using design knowledge to isolate the latent need. This theoretical development shows that latent need finding must go beyond a deductive focus, to developing methods that are able to conjecture with the deduced facts in order to abduce the latent user need.

Product-Service Systems (PSS) are seen as key enablers of circularity. However, better sustainability performance of PSS when compared to transactional business models is not given and it must be carefully considered in the design process. The early-stage PSS design is considered crucial because it determines most of the future offerings' impact. Nevertheless, manufacturing companies struggle with PSS design and often rely on ad hoc intuitive approaches with low success rates. Current PSS design approaches have been dispersed in literature until a recent systematic literature review by the authors proposed a comprehensive generic process model to enable the inclusion of sustainability considerations in the early stages. This paper takes the generic process model as a starting point and instantiates it to the context of two manufacturing companies, seeking to (i) explore the instantiation process from a generic to company-specific process models to support manufacturing companies; and (ii) reflect upon and prepare an evaluation of the generic process model concerning eight predefined criteria. The study reveals a number of potential areas for improving both generic and instantiated process models.

Objective of this contribution is to present the use of Model-based Systems Engineering within the engineering design community. Based on a differentiation between SE and MBSE, the definition of three core MBSE elements, namely modelling method, modelling language, and modelling tool as well as the three major aspects of a consistent system model (requirements, behaviour, and structure) a structured review is conducted, focussing on the understanding and motivation as well as the modelling of systems. The review includes 93 publications from Design Society library and proceedings of the CIRP Design conferences during the period from 2011 to 2022. The review points out, that there is an increasing application of MBSE within the engineering design community, mainly focussing on architecture definition or combined engineering activities. Only a small portion of works (16 publications) are providing a consistent approach as these publications link all aspects of the system model and consider all three MBSE elements. It can be concluded, that there is a diffuse understanding of MBSE and different motivations are given to apply more formal system models as well as modelling tools.

Due to an expanding number of mechatronic functionalities in modern technical products, the proportion of software and electronic components is also increasing. As a result, the products are developed by different engineering domains in complex development processes. To handle the growing complexity, Systems Engineering (SE) is increasingly important for development organizations of enterprises. System Engineering (SE) is understood as an approach to network the individual engineering domains and shall lead to a collaborative development of complex systems. Model-Based System Engineering (MBSE) expands SE by using common models and software tools to describe und visualize the systems. However, MBSE is not widely established in enterprises today. On the one hand, the introduction requires a distinct and consistent system understanding and collaborative way of working. On the other hand, the application of the existing tools requires extensive tool competencies due to many possible functions and features. Therefore, this paper presents a concept and a software based tool for a lean implementation of SE/MBSE to support the collaborative development of complex technical systems in small and medium-sized enterprieses.

A multi-domain Matrix (MDM) is used to identify and analyse rework loops within the Building Design (BD) process caused by building regulations. To model this process, we used information from official documents, plans of work, email archives, and anecdotal evidence as a case study. Findings reveal that MDM can identify the rework loops caused by building regulations, this information forms the basis to improve current BD processes. The complexity of the rework loop including the processes, people and, deliverables involved in the rework loop is also identified. Further analysis can also use the MDM to estimate the costs incurred with each rework cycle. This MDM can also identify rework loops in other engineering design processes due to design changes.

This study is part of a PhD project exploring engineering productivity in the construction industry using DRM. The results present an MDM that provides situation-specific insight, offering areas of process improvement, and support through engineering productivity measurement. This is one of the few studies that models rework loops in the BD process caused by regulations.

Revolutionary changes of a VUCA-world are effecting more and more industries. Focusing the automotive industry, this is caused by several new trends in technology or market. This situation is requiring high flexibility and is questioning for sustainability as well as resilience in system development projects. This publication represents results out of a survey, part of a wider research. The objective is the development of a process orientated method for risk and technical change management. The survey is conducted by participants of transdisciplinary system development in automotive industry. Topics questioned are VUCA, complexity, (re-)action, quality and module interfaces of Generic Systems Engineering. The results demonstrate the participants’ experience and demands for sustainable and resilient system development projects. In conclusion, this report provides information on the considering elements to develop a process orientated method for risk and technical change management in automotive industry.

Testing activities to gain specific design knowledge play an essential role in engineering design, when a structure needs to be developed, for which knowledge from analytical models or documentation is missing. As research into these testing activities is difficult, few insights into successful approaches exist.

In this contribution, we investigate testing activities to gain specific design knowledge through a laboratory task, where 10 engineering students optimize a system using a web-based process chain including rapid prototyping and testing. Design and testing data are acquired from 110 prototypes in 3 hours. A differentiation of performance is conducted and approaches of high- and low-performers are investigated to identify patterns.

Based on these patterns, hypotheses, and metrics indicating successful and non-successful approaches are derived as basis for development of metrics for testing to gain specific design knowledge. A successful approach was overstep the limit, where participants accept destruction of their system to identify boundaries. An unsuccessful approach was the change of many parameters in later tests. These hypotheses and their metrics can then be used in development and validation of support for testing.

Design process modelling is well-founded in fields of mechanical engineering, and product design and development but not in Building Design (BD). This paper looks at the selection process when choosing appropriate models for specific BD processes. The paper adapts process model selection criteria from Trauer's work and combines it with anecdotal evidence from the authors to select these models. The selection criteria were ranked, categorised, and applied to BD processes explained. Process models related to each selection criteria were then selected from backward snowballing of literature.

Process modelling (PM) is used to support designers by providing guidance on what needs to be done. Change processes in development organizations accompany introduction of new procedures, new methods (also digital form), tools that have to integrated into existing processes. Objective of this paper is to provide guidance to designers in selecting the appropriate PM language to support structured changes in processes. Requirements are derived from frequent change needs in SME and a PM morphology is provided assisting the selection and use of suitable PM languages for change processes.

The process of generating FMEA following document-centric approach is tedious and susceptible to human error. This paper presents preliminary methodology for robotic manufacturing process modelling in MBSE environment with a scope of automating multiple steps of the modelling process using ontology. This is followed by the reasoning towards automatic generation of process FMEA from the MBSE model. The proposed methodology allows to establish robust and self-synchronising links between process-relevant information, reduce the likelihood of human error, and scale down time expenses.

As the society is already permeated by data, a data-driven approach to inform design for sustainable behaviour can help to identify misbehaviours and target sustainable behaviours to achieve, as well as to select and implement the most suitable design strategies to promote a behavioural change and monitor their effectiveness. This work addresses the open challenge of providing designers with a model for Human-Machine Interactions (HMI) that helps to identify relevant data to collect for inferring user behaviour related to environmental sustainability during product use.

We propose a systematic modelling framework that combines constructs from existing representation techniques to identify the most critical variables for resources consumption, which are the determinants of potential misbehaviours related to HMI. The analysis is represented as a Behaviour-Inefficiency Model that graphically supports the analyst/designer to link user behaviours with a quantitative representation of resources consumption.

The paper describes the model through an example of the use of a kettle and an additional application of the same approach to a washing machine, in order to point out its versatility for modelling more complex interactions.

Process models are among the principal artefacts used for managing design projects. However, the selection of effective modelling approaches can be difficult for design project managers, given that a plethora of tools exists for various modelling purposes. In addition to date no systematic approach for the assessment and selection of process modelling approaches is available to practitioners. This paper presents the development of criteria for benchmarking and selecting different process modelling tools. The results are based on three elements. (1) In a four-hour workshop undertaken by the Design Process SIG of the Design Society, bringing together around 20 international researchers and practitioners in design process modelling, an initial set of 58 criteria were brainstormed and consolidated during the workshop and in follow-up meetings. (2) The consolidated criteria were then compared with literature. The finalised criteria list was then validated by external experts in industry (3). The resulting list of 12 criteria provides a sound basis for practitioners to support a systematic selection of process modelling approaches. Further, it lays the foundation of a benchmarking tool, which is subject to future work.

The presented research aims at modelling and formalising the process of team design activity as an interplay between the evolution of design problems and solutions. The motivation founds primarily on a presumption that there exist regularities in designing which can be captured and formalised using the appropriate models. The study thus investigates whether the identified design operation proportions and sequence probabilities are consistent throughout the different parts of team conceptual design activities. It does so by exploring the utility of mathematical models built based on the correlations and statistically significant sequences underlying the previously identified designing patterns. The developed mathematical model was tested by replicating moving-average analyses of design operation proportions and sequences, which were originally observed in the protocol analysis study. A close fit was found between the simulated and the observed data, particularly in providing insights regarding operation patterns and proportion trends. The presented models and modelling methodology are potentially an appropriate means for the next steps in describing, and consequently predicting and supporting team design activity dynamics.

Additive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

In our modern, interconnected and globalized world, design is in motion, to adapt to new situations. But successful Design in Motion must be based on Processes in Motion. For a target-oriented adaptation of the processes to the new, challenging conditions, the as-is procedures must be captured and analysed. For this analysis, established capturing procedures from production or administration cannot be used due to some special features of design processes and workflows, which will be discussed in this contribution. To compensate for the weaknesses of existing methods, we propose an adapted method for holistic design process capturing. With the procedure, we want to enable an economic process analysis, which is crucial for small and medium-size companies in particular. To give an insight into the practical application of the method, we exemplarily analyse the process of a shaft construction and FEM-evaluation by two different employees. Based on this analysis and to verify the relevance of the presented approach, an evaluation with respect to the requirements is done.

A comminution process is a material size reduction and separation process which is primarily used in the aggregates and the minerals processing industry. Knowledge related to equipment’s operation, raw material properties, operational strategies, control system, maintenance, etc. is needed to design a capable plant. New needs are arising from the industry for existing operational crushing plants such as investigation for improvements, upscaling, and downscaling of the capacity. The paper presents an application of simulation-driven development for a crushing plant in an existing gold processing plant. Due to the change in ore characteristics and the need for optimizing the cost of operation, it is required to investigate the opportunities for improvement and alternative options for downscaling the capacity of the plant. A systematic process for configuring, developing, and evaluating alternative concepts using a process simulation tool is presented. The results show the process of generating knowledge for alternative crushing plant operation settings and how the choices can be selected and eliminated using boundary conditions. The evaluation presents possible improvements and alternative concepts with their opportunities and pitfalls.

Industrial digital transformation is bringing a need for new tools and concepts. However, designing such complex tools and concept requires methods to be correctly implemented. These methods are studied as part of system engineering to satisfy various identified goals, and more specifically human-system integration, which is the topic of this paper. This article introduces the method used to define key elements of human perception of reality called reality anchors to design scenarios to be tested in a digital twin prototype. This method goes from regulation study to user cognitive function analysis on the specific case of digital twin designing in oil-and-gas industry. This method highlighted the differences between theoretical process and the followed process as well as tools and competencies used to identify reality anchors. This knowledge will then be used to implement a new process to be implemented with a digital twin and scenarios to test the prototype using realistic simulation.