Table Of ContentDesigning Complex Products with
Systems Engineering
Processes and Techniques
Completely revised including six new chapters, this new edition presents a more
comprehensive knowledge of issues facing developers of complex products and pro-
cess management. It includes more tools for implementing a Systems Engineering
approach to minimize the risks of delays and cost overruns and helps create the right
product for its customers.
Designing Complex Products with Systems Engineering Processes and Techniques,
Second Edition highlights how to increase customer satisfaction, quality, safety, and
usability to meet program timings and budgets using a Systems Engineering
approach. It provides decision-making considerations and models for creating sus-
tainable product design and describes many techniques and tools used in product
development and the product life-cycle orientation. The book also offers techniques
used in Design for Manufacturing, Design for Assembly, and product evaluation
methods for verification and validation testing. Many new examples, case studies, six
new chapters, and updated program and data charts held on our website are offered.
The book targets practicing engineers, engineering management personnel, prod-
uct designers, product planners, product and program managers in all industrialized
and developing countries. In addition, the book is also useful to undergraduate, grad-
uate students, and faculty in engineering, product design, and product project and
program management.
Designing Complex
Products with Systems
Engineering Processes
and Techniques
Second Edition
Vivek D. Bhise
Second edition published 2023
by CRC Press
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and by CRC Press
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CRC Press is an imprint of Taylor & Francis Group, LLC
© 2023 Vivek D. Bhise
First edition published by CRC Press 2013
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ISBN: 978-1-032-20369-0 (hbk)
ISBN: 978-1-032-20371-3 (pbk)
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DOI: 10.1201/9781003263357
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Contents
Preface for the First Edition ..................................................................................xxiii
Preface for This Second Edition ............................................................................xxv
Website Materials .................................................................................................xxvii
Acknowledgments .................................................................................................xxix
Author ...................................................................................................................xxxi
Part I Systems Engineering Concepts, Issues, and
Methods in Product Design
Chapter 1 Introduction to Products, Processes, and Product Development .........3
Introduction and Objectives .................................................................3
Understanding Products, Customers, Processes, and Systems ............4
What Is a Product? ..........................................................................4
Who Is the Customer? ....................................................................5
What Are Customer Needs? ............................................................6
What Is a Process? ..........................................................................6
Designing a Complex Product .............................................................9
Definition of a System ....................................................................9
Systems, Subsystems, and Components .......................................10
Systems Work with Other Systems ...............................................11
Product Families and Component Sharing ...................................11
Product Development....................................................................12
Processes in Product Development ..........................................12
Flow Diagram of Product Development ..................................14
Managing the Complex Product ..............................................15
Life Cycle Stages of a Product .....................................................17
Program Phases, Reviews, and Milestones ..............................17
Concluding Remarks .........................................................................20
References .........................................................................................21
Chapter 2 Systems Engineering and Other Disciplines in Product Design .......23
Introduction .......................................................................................23
Systems Engineering Fundamentals ..................................................23
What Is Systems Engineering? .....................................................23
Managing a Complex Product ......................................................26
Systems Engineering Processes in Product Development .................27
Systems Engineering Process .......................................................27
Five Loops in the Systems Engineering Process ..........................28
v
vi Contents
Major Tasks in the Systems Engineering Process.........................30
Requirements Analysis .............................................................30
Functional Analysis and Allocation .........................................31
Design Synthesis ......................................................................31
Verification ...............................................................................32
Validation .................................................................................32
Verification versus Validation ..................................................33
Subsystems and Components Development .................................33
Example of Cascading a Requirement from the Product
Level to a Component Level .........................................................34
Iterative Nature of the Loops within the Systems
Engineering Process ......................................................................35
Incremental and Iterative Development Approach .......................35
Systems Engineering “V” Model ......................................................38
NASA Description of the Systems Engineering Process ..................40
Managing the Systems Engineering Process .....................................42
Relationship between Systems Engineering and Program
Management .................................................................................42
Role of Systems Engineers ................................................................43
Integrating Engineering Specialties into the Systems
Engineering Process ......................................................................44
Role of Computer-Assisted Technologies in Product Design ...........45
CAD and CAE ..............................................................................45
Model-Based Systems Engineering ...................................................45
Importance of Systems Engineering ..................................................46
Advantages and Disadvantages of the Systems Engineering
Process ...............................................................................................47
Some Challenges in Complex Product Development ........................47
Concluding Remarks .........................................................................48
References .........................................................................................49
Chapter 3 Decision-Making and Risks in Product Programs .............................51
Introduction .......................................................................................51
Problem-Solving Approaches ............................................................52
Decision-Making ...............................................................................53
Alternatives, Outcomes, Payoffs, and Risks .................................53
Maximum Expected Value Principle ............................................53
Other Principles ............................................................................55
Techniques Used in Decision-Making ...............................................58
Analytical Hierarchical Method ...................................................58
Weighted Total Score for Concept Selection ................................62
Informational Needs in Decision-Making .........................................63
Decision-Making in Product Design .................................................64
Key Decisions in Product Life Cycle............................................64
Contents vii
Trade-Offs during Design Stages ..................................................64
Risks in Product Development and Product Uses .............................65
Definition of Risk and Types of Risks in Product
Development .................................................................................68
Types of Risks during Product Uses .............................................69
Risk Analysis .....................................................................................69
Risk Matrix ...................................................................................70
Risk Priority Number and Nomographs .......................................71
Problems in Risk Measurements ..................................................72
Importance of Early Decisions during Product Development ...........73
Concluding Remarks .........................................................................73
References .........................................................................................74
Chapter 4 Product Attributes, Requirements, and Allocation of
Functions ...........................................................................................75
Introduction .......................................................................................75
Attributes and Requirements .............................................................75
What Is an Attribute? ....................................................................75
Importance of Attributes ...............................................................76
What Is a Requirement? ................................................................76
Attribute Requirements .................................................................77
Why “Specify” Requirements? .....................................................77
How Are Requirements Developed? .............................................77
Characteristics of a Good Requirement ........................................78
Types of Requirements ......................................................................79
Customer Requirements ................................................................79
Functional Requirements ..............................................................79
Performance Requirements ...........................................................80
Interface Requirements .................................................................80
Reliability Requirements ..............................................................80
Environmental Requirements........................................................80
Human Factors Requirements .......................................................81
Safety Requirements .....................................................................81
Security Requirements ..................................................................81
Designed-to-Conform versus Manufactured-to-Conform
Requirements ................................................................................81
Where Are Requirements Stored? ................................................82
Requirements Allocation and Analysis ..............................................82
Requirements Allocation ..............................................................82
Requirements Analysis .................................................................82
Attributes Development .....................................................................83
Cascading Attribute Requirements to Lower Levels ....................84
Dividing the Product into Manageable Levels ..............................85
Relating Attribute Structure to Systems ............................................86
viii Contents
An Example: Attributes, System Decomposition, and
Requirements for Vehicle Exterior Lighting System ....................87
Attributes ..................................................................................88
Systems and Subsystems..........................................................88
Relationship between System Components and
Requirements ...........................................................................89
Requirements of Exterior Lighting System .............................89
Verification Tests ......................................................................89
An Example: Cascading of Vehicle Level Sub-attribute
Requirements into Powertrain Subsystem Requirements .............91
An Example: Attributes, Requirements, and Trade-Offs in
Suspension Systems of a Sports Car .............................................91
Attributes ..................................................................................91
Requirements ...........................................................................91
Trade-Offs ................................................................................92
Factors Affecting Requirements ........................................................93
Role of Standards in Setting Requirements .......................................94
Types of Standards ........................................................................94
Advantages of Standards ..............................................................95
Disadvantages of Standards ..........................................................96
Problems with Standards ..............................................................96
Standards Development Process ...................................................97
Concluding Remarks .........................................................................98
References .........................................................................................98
Chapter 5 Understanding and Managing Interfaces ...........................................99
Introduction .......................................................................................99
Interface Definition, Types, and Requirements .................................99
What Is an Interface? ....................................................................99
Types of Interfaces ......................................................................100
Interface Requirements ...............................................................102
Visualizing Interfaces ......................................................................103
Interface Diagram .......................................................................104
Interface Matrix and N-Squared Diagram ..................................104
Examples of Interface Diagrams and Interface Matrices ................106
Laptop Computer Interfaces .......................................................106
Automotive Fuel System Interfaces ............................................110
Illustration of Use of Information Contained in Interface
Matrix ..............................................................................................113
Clustering and Sequencing of Matrix Data .....................................115
Teamwork in Interface Management ...............................................118
Establishment of Interface Control ..................................................119
Concluding Remarks .......................................................................119
References .......................................................................................120
Contents ix
Chapter 6 Detailed Engineering Design during Product Development ...........121
Introduction .....................................................................................121
Engineering Design .........................................................................121
Six Product Examples ......................................................................123
Illustration of Wind Turbine Design Using Systems
Engineering “V” Model ...................................................................129
Left Side of the “V”—Design and Engineering .........................129
Right Side of the “V”—Verification, Manufacturing, and
Assembly ....................................................................................131
Right Side of the Diagram—Operation and Disposal ................131
Activities in Engineering Design .....................................................132
Concluding Remarks .......................................................................135
References .......................................................................................135
Chapter 7 Product Evaluation, Verification, and Validation .............................137
Objectives and Introduction .............................................................137
Why Evaluate, Verify, and Validate? ...............................................137
Testing, Verification, and Validation ...........................................137
Distinctions between Product Verification and Product
Validation ....................................................................................138
Overview on Evaluation Issues........................................................138
Types of Evaluations ...................................................................140
Evaluation Methods: An Overview..................................................141
Methods of Data Collection and Analysis .......................................143
Observation Methods ..................................................................143
Communication Methods ............................................................143
Experimentation Methods ...........................................................144
Objective Measures and Data Analysis Methods ............................144
Subjective Methods and Data Analysis ...........................................145
Rating on a Scale ........................................................................145
Analysis of 10-Point Ratings Data .............................................150
Paired Comparison-Based Methods............................................151
Evaluations during Product Development .......................................152
Verification Plan and Tests ..........................................................153
Validation Plan and Tests ............................................................154
Concluding Remarks .......................................................................158
References .......................................................................................158
Chapter 8 Program Planning and Management ...............................................159
Introduction .....................................................................................159
Program versus Project Management ..............................................159
Program Management Functions ................................................160
Development of Detailed Project Plans ......................................160
