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In this post, I want to explain why Model-Based Systems Engineering (MBSE) and Sustainability are closely connected. I would claim sustainability in our PLM domain will depend on MBSE.

Can we achieve Sustainability without MBSE? Yes, but it will be costly and slow. And as all businesses want to be efficient and agile, they should consider MBSE.

What is MBSE?

The abbreviation MBSE stands for Model-Based Systems Engineering, a specialized manner to perform Systems Engineering. Look at the Wikipedia definition in short:

MBSE is a technical approach to systems engineering that focuses on creating and exploiting domain models as the primary means of information exchange rather than on document-based information exchange.

Model-Based fits in the digital transformation scope of PLM – from a document-based approach to a data-driven, model-based one. In 2018, I focused on facets of the model-based enterprise and related to MBSE in this post: Model-Based: System Engineering (MBSE).

My conclusion in that post was:

Model-Based Systems Engineering might have been considered as a discipline for the automotive and aerospace industry only. As products become more and more complex, thanks to IoT-based applications and software, companies should consider evaluating the value of model-based systems engineering for their products/systems.

I drew this conclusion before I focused on sustainability and systems thinking. Implementing sustainability concepts, like the Circular Economy, require more complex engineering efforts, justifying a Model-Based Systems Engineering approach. Let’s have a look.

If you want to learn more about why we need MBSE, look at this excellent keynote speech lecture from Zhang Xin Guo at the Incose 2018 conference below:

The Mission / the stakeholders

A company might deliver products to the market with the best price/quality ratio and regulatory compliance,  perceived and checked by the market. This approach is purely focusing on economic parameters.

There is no need for a system engineering approach as the complexity is manageable. The mission is more linear,  a “job to do,” and a limited number of stakeholders are involved in this process.

… with sustainability

Once we start to include sustainability in our product’s mission, we need a systems engineering approach, as several factors will push for different considerations. The most obvious considerations are the choice of materials and the optimizing the production process (reducing carbon emissions).

However, the repairability/serviceability of the product should be considered with a more extended lifetime vision.

What about upgradeability and reusing components? Will the customer pay for these extra sustainable benefits?

Probably Yes, when your customer has a long-term vision, as the overall lifecycle costs of the product will be lower.

Probably No if none of your competitors delivers non-sustainable products much cheaper.

As long as regulations will not hurt traditional business models, there might be no significant change.

However, the change has already started. Higher energy prices will impact the production of specific resources and raise costs. In addition, energy-intensive manufacturing processes will lead to more expensive materials. Combined with raising carbon taxes, this will be a significant driver for companies to reconsider their product offering and manufacturing processes.

The more expensive it becomes to create new products, the more attractive repairable and upgradable products will become. And this brings us to the concept of the circular economy, which is one of the pillars of sustainability.

In short, looking at the diagram – the vertical flow from renewables and finite materials from part to product to product in service leads ultimately to wasted resources if there are no feedback loops. This is the traditional product delivery process that most companies are using.

You can click on the image to the left to zoom in on the details.

The renewable loop on the left side of the diagram is the usage of renewables during production and the use of the product. The more we use renewables instead of fossil fuels, the more sustainable this loop will be. This is the area where engineers should use simulations to find the optimal manufacturing processes and product behavior. Again click on the image to zoom in on the details.

The right side of the loop, related to the materials, is where we see the options for repairable, serviceable, upgradeable, and even further refurbishment and recycling to avoid leakage of precious materials. This is where mechanical engineers should dominate the activities.  Focussing on each of the loops and how to enable them in the product.  Click on the image to see the relevant loops.

Looking at the circular economy diagram, it is clear that we are no longer talking about a linear process – it has become the implementation of a system. Systems Engineering or MBSE?

The benefits of MBSE

Developing products with the circular economy in mind is no longer a “job to do,” a simple linear exercise. Instead, if we walk down the systems engineering V-shape, there are a lot of modeling exercises to perform before we reach the final solution.

To illustrate the benefits of MBSE, let’s walk through the following scenario.

A well-known company sells lighting projects for stadiums and public infrastructure. Their current business model is based on reliable lighting equipment with a competitive price and range of products.

Most of the time, their contracts have clauses about performance/cost and maintenance. The company sells the products when they win the deal and deliver spare parts when needed.

Their current product design is quite linear – without systems engineering.

Now this company has decided to change its business model towards Product As A Service, or in their terminology LaaS (Lightening as a Service). For a certain amount per month, they will provide lighting to their customers, a stadium, a city, and a road infrastructure.

To implement this business model, this is how they used a Model-Based Systems Engineering approach.

Modeling the Mission

Example of a business model

Before even delivering any products, the process starts with describing and analyzing the business model needed for Lightening as a Service.

Then, with modeling estimates about the material costs, there are exercises about the resources required to maintain the service, the potential market, and the possible price range.

It is the first step of using a model to define the mission of the service. After that, the model can be updated, adjusted, and used for a better go-to-market approach when the solution becomes more mature.

Part of the business modeling is also the intention to deliver serviceable and upgradeable products. As the company now owns the entire lifecycle, this is the cheapest way to guarantee a continuous or improved service over time.

Modeling the Functions

Example of a function diagram

Providing Lighting as a Service also means you must be in touch with your installations in real time. Power consumption needs to be measured and analyzed in real-time for (predictive) maintenance, and the light-providing service should be as cheap as possible during operation.

Therefore LED technology is the most reliable, and connectivity functions need to be implemented in the solution. The functional design ensures installation, maintenance and service can be done in a connected manner (cheapest in operation – beneficial for the business).

Modeling the Logical components

As an owner of the solution, the design of the logical components of the lighting solution is also crucial. How to address various lighting demands efficiently? Modularity is one of the first topics to address. With modular components, it is possible to build customer-specific solutions with a reduced engineering effort. However, the work needs to be done by generically designing the solutions and focusing on the interfaces.

Example of a logical diagram

Such a design starts with a logical process and flow diagrams combined with behavior modeling. Without already having a physical definition, we can analyze the components’ behavior within an electrical scheme. Decisions on whether specific scenarios will be covered by hardware or software can be analyzed here. The company can define the lower-level requirements for the physical component by using virtual trade-offs on the logical models.

At this stage, we have used business modeling, functional modeling and logical modeling to understand our solution’s behavior.

Modeling the Physical product

The final stage of the solution design is to implement the logical components into a physical solution. The placement of components and interfaces between the components becomes essential. For the physical design, there are still a lot of sustainability requirements to verify:

• Repairability and serviceability – are the components reachable and replaceable? Reducing the lifecycle costs of the solution
• Upgradeability – are there components that can behave differently due to software choices, or are there components that can be replaced with improved functionality. Reducing the cost of creating entirely new solutions.
• Reuse & recyclable – are the materials used in the solution recyclable or reusable, reducing the cost of new materials or reducing the cost of dumping waste.
• RoHS/ REACH compliance

The image below from Zhang Xin Guo’s presentation nicely demonstrates the iterative steps before reaching a physical product

Before committing to a hardware implementation, the virtual product can be analyzed, behavior can be simulated, and it carbon impact can be calculated for the various potential variants.

The manufacturing process and energy usage during operation are also a part of the carbon impact calculation. The best performing virtual solution, including its simulations models, can be chosen for the realization to ensure the most environmentally friendly solution.

The digital twin for follow-up

Once the solution has been realized, the company still has a virtual model of the solution. By connecting the physical product’s observed and measured behavior, the virtual side’s modeling can be improved or used to identify improvement candidates – maintenance or upgrades. At this stage, the virtual twin is the actual twin of the physical solution. Without going deeper into the digital twin at this stage, I hope you also realize MBSE is a starting point for implementing digital twins serving sustainability outcomes.

The image below, published by Boeing, illustrates the power of the connected virtual and physical world and the various types of modeling that help to assess the optimal solution.

Conclusion

For sustainability, it all starts with the design. The design decisions for the product contribute for 80 % to the carbon footprint of the solution. Afterward, optimization is possible within smaller margins. MBSE is the recommended approach to get a trustworthy understanding and follow-up of the product’s environmental impact.

What do you think can we create sustainable products without MBSE?