Although robustness is an important consideration to guarantee the performance of designs under deviation, systems are often engineered by evaluating their performance exclusively at nominal conditions. Robustness is sometimes evaluated a posteriori through a sensitivity analysis, which does not guarantee optimality in terms of robustness. This article introduces an automated design framework based on multiobjective optimisation to evaluate robustness as an additional competing objective. Robustness is computed as a sampled hypervolume of imposed geometrical and operational deviations from the nominal point. In order to address the high number of additional evaluations needed to compute robustness, artificial neutral networks are used to generate fast and accurate surrogates of high-fidelity models. The identification of their hyperparameters is formulated as an optimisation problem. In the frame of a case study, the developed methodology was applied to the design of a small-scale turbocompressor. Robustness was included as an objective to be maximised alongside nominal efficiency and mass-flow range between surge and choke. An experimentally validated 1D radial turbocompressor meanline model was used to generate the training data. The optimisation results suggest a clear competition between efficiency, range and robustness, while the use of neural networks led to a speed-up by four orders of magnitude compared to the 1D code.

Seasonal effects can significantly impact the robustness of socio-technical systems (STS) to demand fluctuations. There is an increasing need to develop novel design approaches that can support capacity planning decisions for enhancing the robustness of STS against seasonal effects. This paper proposes a new network motif-based approach to supporting capacity planning in STS for an improved seasonal robustness. Network motifs are underlying nonrandom subgraphs within a complex network. In this approach, we introduce three motif-based metrics for system performance evaluation and capacity planning decision-making. The first one is the imbalance score of a motif (e.g., a local service network), the second one is the measurement of a motif’s seasonal robustness, and the third one is a capacity planning decision criterion. Based on these three metrics, we validate that the sensitivity of STS performance against seasonal effects is highly correlated with the imbalanced capacity between service nodes in an STS. Correspondingly, we formulate a design optimisation problem to improve the robustness of STS by rebalancing the resources at critical service nodes. To demonstrate the utility of the approach, a case study on Divvy bike-sharing system in Chicago is conducted. With a focus on the size-3 motifs (a subgraph consisting three docked stations), we find that there is a significant correlation between the difference of the number of docks among the stations in a motif and the return/rental performance of such a motif against seasonal changes. Guided by this finding, our design approach can successfully balance out the number of docks between those stations that have caused the most severe seasonal perturbations. The results also imply that the network motifs can be an effective local structural representation in support of STS robust design. Our approach can be generally applied in other STS where the system performances are significantly impacted by seasonal changes, for example, supply chain networks, transportation systems and power grids.

The diversity of design research studies and their associated methods and reporting style make it difficult for the design research community of practice to leverage its work into further advancing the field. We illustrate how a structured multilevel analysis of diverse studies creates a canonical model that allows for the transfer of insight between studies, enhances their comprehension, and supports improved study designs. The benefits of such an approach will increase if different stakeholders adopt such structured approaches to enrich the design research community of practice.

Interdisciplinary engineering of cyber physical production systems (CPPS) are often subject to delay, cost overrun and quality problems or may even fail due to the lack of efficient information exchange between multiple interdisciplinary teams working in complex networks within and across companies. We propose a direct integration of multiteam and organisational aspects into the graphical notation of the systems engineering workflow. BPMN++, with eight new notational elements and two subdiagrams, enables the modelling of the required cooperation aspects. BPMN++ provides an improved overview, uniform notation, more compact presentation and easier modifiability from an engineering point of view. We also included a first set of empirical studies and historical qualitative and quantitative data in addition to subjective expert-based ratings to increase validity. The use case introduced to explain the procedure and the notation is derived from surveys in plant manufacturing focussing on the start-up phase and decision support at site. This, in particular, is one of the most complex and critical phases with potentially high economic impact. For evaluation purposes, we compare two alternative solutions for a short-term management decision in the start-up phase of CPPS using the BPMN++ approach.

Interdisciplinary programmes have become common in universities and research groups’ curricula. This study conducted a network analysis on a Korean university’s undergraduate curriculum and used several visualisation tools to assess keywords across courses and departments, revealing epistemological distances between the courses/departments and their concepts of study. This data-driven methodology defined the characteristics of close or neighbouring departments, making it possible to implement narrow interdisciplinarity through common subjects within the courses. Interestingly, a further projected network could determine the implicit relations between departments that are not considered close, which would make it possible to implement a wide interdisciplinary curriculum. The data-driven network analysis conducted in this study contributes to searching for new programmes for specific levels of interdisciplinarity on an empirical basis.

Robust designs protect system utility in the presence of uncertainty in technical and operational outcomes. Systems-of-systems, which lack centralized managerial control, are vulnerable to strategic uncertainty from coordination failures between partially or completely independent system actors. This work assesses the suitability of a game-theoretic equilibrium selection criterion to measure system robustness to strategic uncertainty and investigates the effect of strategically robust designs on collaborative behavior. The work models interactions between agents in a thematic representation of a mobile computing technology transition using an evolutionary game theory framework. Strategic robustness and collaborative solutions are assessed over a range of conditions by varying agent payoffs. Models are constructed on small world, preferential attachment and random graph topologies and executed in batch simulations. Results demonstrate that systems designed to reduce the impacts of coordination failure stemming from strategic uncertainty also increase the stability of the collaborative strategy by increasing the probability of collaboration by partners; a form of robustness by environment shaping that has not been previously investigated in design literature. The work also demonstrates that strategy selection follows the risk dominance equilibrium selection criterion and that changes in robustness to coordination failure can be measured with this criterion.

Mass Personalisation (MP) is becoming more significant to answer diversifying customer needs, as a result of the advancements in digital manufacturing. In contrary to the modular design in mass customisation, Design for MP (DfMP) proposes more profound changes in product and active user involvement in the design process, while maintaining mass efficiency. Traditional product development methodologies fall short in guiding MP, as it has the distinct differences with product variability and the customer involvement with specific needs. In this study, a dedicated design methodology for MP is presented, focussing on these key dimensions. The proposed methodology guides the designer through the development process of a user modifiable design and demonstrates how to facilitate the user involvement in reaching a personalised design. It proposes a flexible and adaptable seed design architecture, and an interactive customer co-creation process. The development of a seed design, construction of its design space, and management of the solution space with a design solution algorithm are elaborated. The application of the methodology was illustrated on the personalisation of knitted footwear, and 3D printed saxophone mouthpiece. The examples show the potential of the methodology to deal with coupled MP cases. A systematic approach to DfMP will allow expanding MP to more products, and acts as a foundation for the customer co-creation oriented design in the context of this emerging paradigm.

Recent years have seen the rise of citizens as contributors to hardware product creation. This trend has increased attention to open source hardware (OSH): a phenomenon that extends the intellectual property management and development practices in open source software (OSS) into the design of physical objects. OSH projects are different from OSS projects due to product type, and distinct from traditional closed source new product development (NPD) ones due to their openness. These differences challenge the degree of applicability of existing project success definitions in the OSH context. To investigate project success in OSH, we conducted a qualitative survey with practitioners. We report characteristics of successful OSH projects through three identified themes: (a) value creation – the big-picture impact, (b) quality of output – the quality of the hardware and accompanying documentation and (c) project process – activities that contribute to success. We contextualise by comparing OSH with selected literature on the success of OSS and NPD project management. While our study confirms a similarity between OSS and OSH in defining project success, it also highlights themes that are uniquely important to the latter. These findings are helpful for OSH development practice and could provide lessons for OSS development and closed source NPD.

Engineering design induces mental stress for students and the sources of stress for each stage of design are unique. Therefore, strategies are needed to manage the stress of engineering design that are applicable across the design process. This study investigated the effect of a brief mindfulness-based intervention on first-year students’ cognitive stress during concept generation, concept selection and physical modelling. It was found that the mindfulness-based intervention did increase one aspect of students’ state mindfulness (though the effect was small). While prior work indicates that increased mindfulness can lower perceived stress, the increase in students’ state mindfulness during this study was not found to have an observable impact on students’ stress experience. However, students were receptive to completing a mindfulness-based activity in-class and perceived multiple benefits. Physical modelling was the most stressful of the design tasks while concept generation and concept selection produced similar levels of stress. Students used five reoccurring mechanisms for coping with the stress of design including focusing on the task, minimising the importance of their performance, breathing, taking a break and avoidance/distraction. More research should be conducted with longer duration mindfulness-based interventions to understand their potential as a stress management strategy for engineering design.

This article proposes the solver-aware system architecting framework for leveraging the combined strengths of experts, crowds and specialists to design innovative complex systems. Although system architecting theory has extensively explored the relationship between alternative architecture forms and performance under operational uncertainty, limited attention has been paid to differences due to who generates the solutions. The recent rise in alternative solving methods, from gig workers to crowdsourcing to novel contracting structures emphasises the need for deeper consideration of the link between architecting and solver-capability in the context of complex system innovation. We investigate these interactions through an abstract problem-solving simulation, representing alternative decompositions and solver archetypes of varying expertise, engaged through contractual structures that match their solving type. We find that the preferred architecture changes depending on which combinations of solvers are assigned. In addition, the best hybrid decomposition-solver combinations simultaneously improve performance and cost, while reducing expert reliance. To operationalise this new solver-aware framework, we induce two heuristics for decomposition-assignment pairs and demonstrate the scale of their value in the simulation. We also apply these two heuristics to reason about an example of a robotic manipulator design problem to demonstrate their relevance in realistic complex system settings.

The uncertainties and variation of additive manufacturing (AM) material properties and their impact on product quality trouble designers. The lack of experience in AM technologies renders the experts’ assessment of AM components and the establishment of safety margins difficult. Consequently, unexpected qualification difficulties resulting in expensive and lengthy redesign processes might arise. To reduce the risk of qualification failure, engineers might perform copious time-consuming and expensive specimen testing in early phases, or establish overconservative design margins, overriding the weight reduction benefits of AM technologies. In this article, a model-based design method is proposed for the conceptual design of AM space components with affordable test phases. The method utilizes fuzzy logics to systematically account for experts’ assessment of AM properties variation, and to provide an early estimation of a product qualification likelihood related to design parameters of interest, without the need for copious testing. The estimation of qualification likelihood can also point out which are the unique AM material uncertainties that require further specific testing, to enable the design of a product with a better performance and more affordable test phases. The method is demonstrated with the design for AM gridded of ion thrusters for satellite applications.

Sustainability considerations are traditionally difficult to trade-off with technical and business requirements in an early design phase. Hence, design teams need support to reflect early on in the process, on how sustainability may affect profitability and customer value fulfilment in the long term. The commoditisation of modelling and simulation techniques points to gamification and serious gaming as emerging approaches to raise awareness among the design team – as well as users and stakeholders – of the expected behaviour of a solution along its life cycle. The objective of this paper is to explore how serious games can be used to inform decision-makers about the value versus cost implications of being (or not being) ‘sustainability compliant’ when designing products and systems. The paper initially presents the findings from a descriptive study focused on the definition of ‘design support’ intended to raise sustainability awareness through serious gaming. It further describes the development, application and testing of one of such games for material selection in the aerospace industry.

Additive manufacturing (AM) has gained prominence over the last 15 years and become a viable manufacturing option. Since there is great industrial interest to implement serial production of products using AM, the education of engineers in design for additive manufacturing (DfAM) is important today. DfAM extends on design for manufacturing to provide knowledge about the new design opportunities enabled by AM. A set of design heuristics for additive manufacturing (DHAM) to assist designers with conceptual-level DfAM has previously been proposed. In this paper, these DHAM are evaluated through workshops with 3 engineering companies and 19 engineers, in which the participants re-design existing company products for AM using the DHAM as an aid, and then give feedback. The DHAM are well received by the workshop participants, and they find that the DHAM are good for teaching others about the capabilities of AM, provide a checklist of items to consider to help avoid oversights, and encourage the generation of new ideas. Criticisms include the number of examples provided and the lack of information about how to implement the ideas concretely. It is also found that the DHAM fulfil 16 of 18 criteria for early design phase DfAM methods, identified in academic literature.

Co-evolution accounts have generally been used to describe how problems and solutions both change during the design process. More generally, problems and solutions can be considered as analytic categories, where change is seen to occur within categories or across categories. There are more categories of interest than just problems and solutions, for example, the participants in a design process (such as members of a design team or different design teams) and categories defined by design ontologies (such as function-behaviour-structure or concept-knowledge). In this paper, we consider the co-evolution of different analytic categories (not just problems and solutions), by focussing on how changes to a category originate either from inside or outside that category. We then illustrate this approach by applying it to data from a single design session using three different systems of categorisation (problems and solutions, different designers and function, behaviour and structure). This allows us to represent the reciprocal influence of change within and between these different categories, while using a common notation and common approach to graphing quantitative data. Our approach demonstrates how research traditions that are currently distinct from each other (such as co-evolution, collaboration and function-behaviour-structure) can be connected by a single analytic approach.

Sustainability encompasses social, economic and environmental issues with the primary aim to fulfil the needs of the present society without compromising the potential needs of future generations. Product design has been identified to greatly influence the sustainability of New Product Development. This study aims to identify and review the fundamental factors in which product design has the ability to influence and improve the overall environmental sustainability of a product. A comprehensive literature review has been performed to establish trends over the past four decades. The factors that have significant potential, such as the 6Rs, waste and energy, which aid designers in the implementation of environmental sustainability during the product design process have been identified and discussed. Through this analysis, a new conceptual framework has been conceived, facilitating designers in implementing environmental sustainability during product development. In addition, future research opportunities have been identified.

Effective stakeholder interviewing is a critical component of a design process. However, interviewing is a complex skill that is difficult for novice designers to learn and incorporate into their design practices. Few studies have investigated how novice designers apply recommended practices for interviewing stakeholders during the development of product requirements. In this research, we studied how novice designers elicited information to inform the development of product requirements during stakeholder interviews. Results included the establishment of a coding methodology developed from a systematic literature review of recommended interviewing practices that was used to reliably evaluate the use of recommended practices in novice designers’ interviews. A correlation existed between the use of recommended practices and the extent to which information gathered from interviews was incorporated into the requirements. Additionally, specific recommended practices, such as encouraging deep thinking and being flexible and opportunistic, differentiated performance among novice designers. The coding methodology could be adapted to guide the development of stakeholder interview protocols and assessment of design interview skills.

Historically, squeak and rattle (S&R) sounds have been among the top quality problems and a major contributor to the warranty costs in passenger cars. Geometric variation is among the main causes of S&R. Though, geometric variation analysis and robust design techniques have been passively involved in the open-loop design activities in the predesign-freeze phases of car development. Despite the successful application of topometry optimisation to enhance attributes such as weight, durability, noise and vibration and crashworthiness in passenger cars, the implementation of closed-loop structural optimisation in the robust design context to reduce the risk for S&R has been limited. In this respect, the main obstacles have been the demanding computational resources and the absence of quantified S&R risk evaluation methods. In this work, a topometry optimisation approach is proposed to involve the geometric variation analysis in an attribute balancing problem together with the dynamic response of the system. The proposed method was used to identify the potential areas of a door component that needed structural reinforcement. The main objective was to enhance the design robustness to minimise the risk for S&R by improving the system response to static geometrical uncertainties and dynamic excitation.

Enterprise social network messaging sites are becoming increasingly popular for team communication in engineering and product design. These digital communication platforms capture detailed messages between members of the design team and are an appealing data set for researchers who seek to better understand communication in design. This exploratory study investigates whether we can use enterprise social network messages to model communication patterns throughout the product design process. We apply short text topic modelling (STTM) to a data set comprising 250,000 messages sent by 32 teams enrolled in a 3-month intensive product design course. Many researchers describe the engineering design process as a series of convergent and divergent thinking stages, such as the popular double diamond model, and we use this theory as a case study in this work. Quantitative and qualitative analysis of STTM results reveals several trends, such as it is indeed possible to see evidence of cyclical convergence and divergence of topics in team communication; within the convergence–divergence pattern, strong teams have fewer topics in their topic models than weaker teams; and teams show characteristics of product, project, course, and other themes within each topic. We provide evidence that the analysis of enterprise social networking messages, with advanced topic modelling techniques, can uncover insights into design processes and can identify the communication patterns of successful teams.

Customers make quick judgments when shopping online based on how they perceive product design features. These features can be visual such as material or can be descriptive like a ‘nice gift’. Relying on feature perceptions can save customers time but can also mislead them to make uninformed purchase decisions, for example, related to sustainability. In a previous study, we developed a method to extract product design features perceived as sustainable from Amazon reviews, identifying that customer perceptions of product sustainability may differ from engineered sustainability. We previously crowdsourced annotations of French press reviews and used a natural language processing algorithm to extract the features. While these features may not contribute to engineered sustainability, customers identify the features as sustainable enabling them to make informed purchase decisions. In this study, we validate how our previously developed method can be generalised by testing it with electric scooters and baby glass bottles. Features perceived as sustainable for both products are extracted and second, participants are tested on interpreting the features using a novel collage approach. Participants placed products on a set of two axes and selected features from a list. Our results confirm that the proposed method is effective for identifying features perceived as sustainable, and that it can generalise for different products with limitations. Positively biased Amazon reviews can limit the natural language processing performance. We recommend that designers use our method when designing products to capture feature perceptions and help inform customer-oriented design decisions.

Empathy is argued to be a key factor for a successful design discussion. However, such causality cannot be empirically proven based on how empathy is currently defined in design community. Empathy is used as an umbrella construct, broad and encompassing of diverse phenomena, making it difficult to quantify. We suggest improving such a situation by introducing a definition of empathy based on psychology literature, which provides structure and guidance for studying the role of empathy in design. We first break empathy to components. Then, we review empathy as used in design. Finally, we synthetize the reviewed material. From this synthesis, we conclude that empathy in design shares several key components of empathy in psychology; particularly with state influences, top-down control process and emotional stimuli. These are present in design methods although they have not been studied using such terms. Incorporating psychological components of empathy into design can help conceptualising empathy from a different angle, thus opening interesting new avenues for future research. We hope that our treatment provides present and future designers with some useful guidance.