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Design Methodology for Future Products

Data Driven, Agile and Flexible

  • 2022
  • Buch
Herausgegeben von
Prof. Dr. Dieter Krause
Emil Heyden
Verlag
Springer International Publishing
Enthalten in
Springer Professional "Wirtschaft+Technik"
Springer Professional "Technik"
Springer Professional "Wirtschaft"
insite
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Über dieses Buch

Design Methodology for Future Products - Data Driven, Agile and Flexible bietet einen Überblick über die aktuellen Forschungsergebnisse auf dem Gebiet der Designmethodik aus Sicht der Mitglieder der Wissenschaftlichen Gesellschaft für Produktentwicklung (WiGeP - Wissenschaftliche Gesellschaft für Produktenwicklung e.V.). Dieses Buch zielt darauf ab, einen Beitrag zu Designmethoden und deren Umsetzung für innovative zukünftige Produkte zu leisten. Der Schwerpunkt liegt dabei auf der entscheidenden datengestützten, agilen und flexiblen Arbeitsweise. Vier Themen werden in den entsprechenden Kapiteln behandelt: Methoden für Produktentwicklung und -management, Methoden für spezifische Produkte und Systeme, Herausforderungen in der Produktentwicklung und modellbasiertes Engineering in der Produktentwicklung. Diese Publikation beginnt mit der agilen strategischen Vorausschau nachhaltiger mechatronischer und cyber-physischer Systeme, geht weiter zu den Themen des Systems Generation Engineering in Entwicklungsprozessen, gefolgt von der technischen Vererbung in der datengetriebenen Produktentwicklung. Produktverbesserungen werden durch agiles erlebnisorientiertes Lernen auf Basis von Reverse Engineering und durch die Kombination von Usability und Emotionen aufgezeigt. Darüber hinaus wird die Entwicklung zukunftsweisender Produkte im Bereich biomechatronischer Systeme, nachhaltiger Mobilitätssysteme und in situ Sensorintegration gezeigt. Die Überwindung von Herausforderungen in der Produktentwicklung wird durch kontextangepasste Methoden demonstriert, die sich auf Effizienz und Effektivität konzentrieren, sowie durch Designer-zentrierte Methoden, um kognitiven Vorurteilen entgegenzuwirken. Das Flow Design für die zielorientierte Verfügbarkeit von Daten und Informationen in der Produktentwicklung wird angesprochen. Themen des modellbasierten Systems Engineering werden auf die funktionsgesteuerte Produktentwicklung übertragen, indem Modellelemente in allen Stadien und Phasen des Produkts miteinander verknüpft werden. Das Potenzial des modellbasierten Systems Engineering für modulare Produktfamilien und des Engineerings multidisziplinärer komplexer Systeme wird aufgezeigt.
Mit KI übersetzt

Inhaltsverzeichnis

Frontmatter

Methods for Product Development and Management

Frontmatter
1. From Agile Strategic Foresight to Sustainable Mechatronic and Cyber-Physical Systems in Circular Economies
Abstract
Today’s entrepreneurial decisions have to be taken under the conditions of volatility, uncertainty, complexity and ambiguity. Future holistic product creation therefore requires suitable methods, tools and models from initial strategic steps to product’s end of life. In order to improve competitiveness and to realize sustainability, common guidelines for management and operations have to be set in company-specific Product Creation Systems (PCS). Entrepreneurial activities at all management and operational levels must be aligned towards short, middle and long-term horizons. In order to provide a holistic framework for such joint orientation, a generic Product Creation System (gPCS) corresponding to the approach of Lean Production Systems is proposed in this chapter. Mechatronic and Cyber-Physical Systems are key elements in large-scale connected systems. They are complemented by smart functions and concepts like digital twins to enable digital business models and to facilitate intelligent use. Innovative digital business models treat sustainability as beneficial objective and thus lay the foundation for Circular Economies. Product engineers are supported in their tasks by means of Digital and Virtual Product Creation. Typically, they are confronted with uncertainty in Product Creation. For instance, engineers need to gather and interpret uncertain information in Strategic Planning about circularity needs and business potentials. Furthermore, potential effects of alternative design concepts on circularity have to be simulated and weighed up in advance during engineering. Therefore, Agile Strategic Planning, Resilient Requirements Engineering as well as Digital Worker and Learning Assistance are identified as key techniques to be merged with Model-Based Systems Engineering (MBSE). Traceable integration into system lifecycle management is key to utilize sustainability potentials along the entire lifecycle.
Iris Gräßler, Jens Pottebaum
2. Model of SGE: System Generation Engineering as Basis for Structured Planning and Management of Development
Abstract
Providing methods and processes for structured planning and management of the development of new systems requires a description model, which describes fundamental phenomena in the development of new systems. Such a model should be based on the theory of socio-technical systems, it should be applicable to the wide range of different types of development projects which are observable in practice and it should provide formalisms for quantitative empirical studies and computer support. The model of SGE—System Generation Engineering aims at this goal. It describes the development of new systems with two fundamental hypotheses. First, every development of a new system is based on a reference system, consisting of subsystems from already existing systems. Second, based on the reference system, the subsystems of a new system are developed by three types of variation: carryover variation, attribute variation and principle variation. The model finds broad approval in development practice and allows also for the description of development increments as well as for the description of production and validation systems. Variation types and characteristics are key factors for innovation potential and development risk in the development of a new system. They are also important factors for the situation specific methodical support of development activities.
Albert Albers, Simon Rapp
3. Technical Inheritance as an Approach to Data-Driven Product Development
Abstract
Hallmarks of modern technical products or systems are an accelerated time-to-market by clear modification cycles, the processing of large amounts of data, an increased flexibility as well as a quick reaction to changes in market situations. The monitoring of technical products is state of the art nowadays. Due to new communication possibilities that have emerged, a multitude of data exist that can be transferred into information and knowledge about products through their life cycle. The developing communication possibilities facilitate new innovative approaches for the application of product life cycle data. New methods of data management and data processing are required for cross-generational process analysis as are software and hardware tools. Furthermore, new methodologies for developing technical products are demanded. This chapter describes the Paradigm of Technical Inheritance, which is based on the idea of developing and modifying a new generation of products or services taking into account the information gathered from the life cycles of the previous generations. The basic principles of this approach are outlined, a process model including data collection, monitoring and analysis methods is presented, and application examples for both a generation-oriented development of a single component and for a complex technical system are given.
Roland Lachmayer, Iryna Mozgova
4. Application of Agile Experiential Learning Based on Reverse Engineering as Support in Product Development
Abstract
In an information society, there is a trend towards finding solutions by researching online references. This possibility must also be used for the product development process. Consequently, this chapter shows a combination of methods between the product development process and reverse engineering. This approach aims to support product planning, task clarification and conception by use of reference fundamentals. For this purpose, iterative empirical values are generated by the model of experiential learning according to LEWIN. This application has been tested by means of hardware development of a condition monitoring system. The experience gained is documented in terms of benefits and restrictions that arise. A recommended course of action in dealing with online media is shown with an application example as a basis for the reverse engineering process. In conclusion, the statement can be made: Employing reverse engineering, online media can make an effective and early knowledge contribution to the product development process.
Frank Mantwill, Valentin Multhauf

Methods for Specific Systems and Products

Frontmatter
5. Improving Products by Combining Usability and Emotions
Abstract
User-friendly and successful products usually emerge when pure functionality meets good usability as well as an emotional and aesthetic design. Modern theoretical approaches consider all of those three aspects as equally important. In practice, however, they are often still treated independently from one another. Thus, neither positive nor negative interdependencies can be taken into account. This chapter tries to close this gap by examining the relationship of usability and emotions and introducing the idea of dual user integration that aims for combining both aspects. A concrete approach to balance both aspects focusing on emotional impressions and physical capacities of the user is presented to make dual user integration applicable. This proactive approach is called Application for Computer-Aided Design of Emotional impressions and Physical capacities (ACADE+P) and consists of three main steps: (1) user/product description, (2) product evaluation and (3) data-based derivation of quantitative recommendations for design improvements. In addition to the general framework, the specific workflow of the method including an analysis and synthesis phase is explained in detail.
Tina Buker, Jörg Miehling, Sandro Wartzack
6. Challenges in the Development of Biomechatronic Systems
Abstract
This book chapter is dedicated to the methodological challenges in the development of biomechatronic systems, which require an integrative consideration of biological and mechatronic systems in the development process. There are no uniform process models, methodologies and tools that structure and support the individual development phases. Rather, it must be stated at the current time of the numerous research activities that appropriate methods and procedures must be conceived and designed for a given development project and goal in the form of a coevolution. This is particularly necessary in the early development phases of biomechatronic systems and thus in the system design. The variety of biomechatronic developments requires situationally adapted procedures as well as a frequently differing but goal-oriented application of analytical, experimental and numerical tools. This applies equally to the two thrusts in the development of biomechatronic systems, which are (bio)medical technology and bionics. Both directions are based on system theoretical approaches in system design, which enable a model-based and finally a simulation-based development of biomechatronic systems. The theoretical explanations of the chapter are exemplified by two current research projects. The development of a movement trainer to promote implant healing of hip end prostheses is addressed as a representative example of medical technology. As an example from bionics, the transfer of musculoskeletal lightweight design to technical applications is thematized.
Marc Neumann, Beate Bender
7. Design Methodologies for Sustainable Mobility Systems
Abstract
The balance between the environment, traffic and freedom of mobility is one of the great challenges of our time. During the last decades, vehicles have become significantly more efficient, however, motorized transport still causes severe negative environmental impacts through the emission of greenhouse gases (GHG), air pollutants and noise, as well as land use and resource consumption. Sustainable mobility has been subject to a large number of research projects on the individual technologies and innovations have been carried out and published. However, most studies only consider individual modes of transport and not the entire transport system. Furthermore, the aspect of sustainability is often limited to environmental issues or GHG emissions. We discuss sustainability in a more holistic approach which integrates environmental, economic and social sustainability and we provide design methodologies and exemplary applications to support the transformation towards sustainable mobility in the future. This should be of interest to both, engineering design researchers and practitioners from the automotive industry as well as fleet operators. The applicability of our methodologies is shown with examples which are taken from current research at TU Berlin as well as solutions which have already been validated in operational application.
Dietmar Göhlich, Anne Magdalene Syré, Michel Joop van der Schoor, Dominic Jefferies, Alexander Grahle, Ludger Heide
8. Methods for In Situ Sensor Integration
Abstract
A novel research topic to accelerate the digitalisation of mechanical engineering is the integration of measuring functions directly into components close to the process at in situ positions. Often it is neither obvious where to measure nor which measurand is suitable to fulfil the required measuring function. Measuring concepts differ in terms of their measuring location, the used physical effects as well as required system and material properties. A methodically supported identification of potential measurands is addressed in this contribution. Therefore, physical effect catalogues are used to establish a connection between different physical quantities. Potential measurands are contrasted by uncertainty regarding the dependencies of the underlying measuring concepts from environmental and boundary conditions. The identification and consideration of uncertainty is mandatory for a reasoned decision for a specific measuring concept. This includes the development of measures to reduce uncertainty based on Robust Design strategies. A methodical approach for the systematic identification and consideration of uncertainty following the Uncertainty Mode and Effects Analysis (UMEA) is described. The chapter concludes by introducing the concept of Sensing Machine Elements (SME) as promising approach for in situ sensor integration in (existing) technical systems, which combine a reduction of additional installation space and uncertainty.
Maximilian Hausmann, Eckhard Kirchner, Gunnar Vorwerk-Handing, Peter Welzbacher

Facing the Challenges in Product Development

Frontmatter
9. Context-Adapted Methods of Modern Product Development: Recommendations and Best Practice Examples
Abstract
Product developers continue to face many challenges when it comes to ensuring the most efficient and effective product development possible. In order to meet these challenges, appropriate support is required. But what do expedient supports look like? This contribution addresses the challenge of developing methods that are as flexible as possible and adapted to the context as a form of expedient support. To this end, general aspects that such a method should take into account are presented at the beginning, as well as the overarching question of what is basically understood by methods that are flexible and adaptable to the context. The core of this contribution is then formed by recommendations for the development of context-adaptable methods and supports. Examples from the institute’s everyday life are used as best practices and briefly presented where possible. The aim is to provide future product developers with suggestions for, in particular, the development of flexible and adaptable methods and also to further minimize the reservations that still exist about this.
Daniel Roth, Hansgeorg Binz
10. An Approach to Develop Designer-Centred Methods: Illustrated by an Example on How to Overcome Cognitive Bias in Product Development
Abstract
Although the designer has been recognized to have a particularly important role in product development, design method development still shows a lack of putting the designer in the focus. This contribution presents an approach to develop designer-centred methods in three steps: Assessment of designer thinking, design method synthesis and design method validation. To illustrate the approach, the development of a design method to overcome cognitive bias in product development is presented using the approach. Cognitive biases are systematic deviations from rational decisions that lead to illogical interpretations of information or data. By taking cognitive bias and designer thinking into consideration, data driven design can be better supported. The method development here addresses the confirmation bias, a particularly difficult bias. With the Design-ACH, a method is presented that supports design engineers in reducing the confirmation bias, which is shown by results of multiple studies. Implications for future development of designer-centred methods include data driven method development, which can be made possible by automated quantitative measurement of designer thinking. Also, there is a need for studies in both laboratory and field to ensure designer-centred method development.
Sven Matthiesen, Thomas Nelius, Matthias Eisenmann
11. Data and Information Flow Design in Product Development
Abstract
The value of product development lies in the generation of data and information to develop technical systems. The development knowledge of companies is stored in processes and methods. In order to be able to use this knowledge, a target-oriented availability of data and information is required. These data and information flows are anchored in the development organization and in the IT structures. This article presents methods for identifying the necessary requirements, analyzing and designing the distribution and use of data and information. In addition to the IT tools, however, the developer in particular is also an important carrier and transmitter of data and information, and must be included in such considerations. Agile development methods address this aspect of supporting communication, co-op-ration and collaboration between developers in order to use the developers’ tacit knowledge on the one hand and to force learning in the development organization on the on the other, thus contributing to knowledge retention. An efficient use of data and information in the development requires that developers use also the available methods. Method acceptance is not given per se. This problem is addressed in the article, and approaches are shown to explain and support data and information flows from both a tool-oriented and a human-oriented perspective.
Kristin Paetzold

Model-Based Engineering in Product Development

Frontmatter
12. Model-Based Systems Engineering: A New Way for Function-Driven Product Development
Abstract
Since the 1950ies Design Theory and Methodology has described product and system development as a process that goes through the stages of requirements definition, considerations of functions, allocation of solution principles and, finally, detailing. Computer support of this process has more or less evolved backwards: Starting with manufacturing information (i.e. supporting processes after product development), going through geometric modelling to simulation—which is basically our present state. Functional modelling and requirements management has been very difficult to realise with conventional methods. Today, Model-Based Systems Engineering (MBSE) offers new ways to come to a holistic coverage of the product development process providing and—very importantly—linking model elements for all of its stages. Starting from the needs, as seen from Design Theory and Methodology, this article describes the current state of MBSE as a new, integrative approach for product and system development and identifies needs for further progress in this field.
Stephan Husung, Christian Weber, Atif Mahboob
13. Function-Oriented Model-Based Product Development
Abstract
The innovative strength and competitiveness of a company depends on mastering the growing complexity of digitally networked products in an efficient way. The complexity is driven by increasing interactions among the different domains, like mechanical, electrical or software engineering on all system levels. The interdependencies require modelling approaches, that allow to explicitly and transparently reveal those interdependencies on requirements, functional architectures and solution level over all phases of the development. The increasing interdependencies and the need for more efficiency forces a change from component oriented, document-based product development to a function-oriented, model-based product development with consistently linked models across all participating domains. We propose a system architecture that describes the system in a comprehensible way across domains. The domains are able to connect their models to the architecture and link them down to the parameter level over requirements, functional architecture to the solution layer. The resulting system model allows a transparent, cross-domain mapping of functional interactions. Principle solution models close the gap between the functional and the solution layer, especially in mechanical engineering. The efficiency in development processes can be significantly increased by using model libraries to assign functions to solution models and by building ontologies to structure domain-specific models.
Georg Jacobs, Christian Konrad, Joerg Berroth, Thilo Zerwas, Gregor Höpfner, Kathrin Spütz
14. Model-Based Systems Engineering: Discovering Potentials for Methodical Modular Product Development
Abstract
A constantly growing market variety results in an increasing internal variety, which is reflected in increased variety costs. In order to cope with this situation, different methods for the development of modular product families and their modular product architectures were developed. During the implementation of these methods, different product data come together, which are linked in different tools. At this point, a document-based approach reaches its limits and inconsistencies occur. To counteract, the trend of Model-Based Systems Engineering (MBSE) is being integrated into methodical modular product development. Using the example of method units of the Integrated PKT Approach for the Development of Modular Product Families, it is shown how the deposit of a meta model of product data enables consistency. The consistent model of the method units Design for Variety and Life Phases Modularization is extended by two elements: Configuration systems and the effects of modular product architectures. A configuration system based on this enables the efficient addressing of customer requirements in sales. The linking of the effects of modular product architectures strengthens the objective of Life Phases Modularization. Furthermore, the resulting consistent overall model generates several analysis options and opens up new possibilities, such as the establishment of Digital Twins.
Dieter Krause, Lea-Nadine Schwede, Florian M. Dambietz, Michael Hanna
15. Methodical Approaches for Engineering Complex Systems
Abstract
Technical systems are becoming increasingly complex due to technological progress, changing customer needs and (market-specific) constraints, e.g. addressing the eco-friendliness of new products. This leads to an increasing complexity of the overall development of these systems. One way of dealing with this complexity during the development is the use of design methodologies in general and especially the methods of systems engineering. A systemic view of the systems as well as of the processes in the sense that the system theory is of central importance for developing complex eco-friendly multidisciplinary systems. This article presents an overview of current research findings to support the development of the aforementioned systems and provides an outlook on how such design methods can contribute to the idea of a Circular Economy.
Thomas Vietor, Tobias Huth
Titel
Design Methodology for Future Products
Herausgegeben von
Prof. Dr. Dieter Krause
Emil Heyden
Copyright-Jahr
2022
Electronic ISBN
978-3-030-78368-6
Print ISBN
978-3-030-78367-9
DOI
https://doi.org/10.1007/978-3-030-78368-6

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