1.2 Fundamentals of Systems Engineering

Systems engineering is a crucial aspect of industrial engineering, focusing on designing and managing complex systems. It employs an interdisciplinary approach, considering the entire lifecycle of a system from concept to retirement, while emphasizing holistic thinking and optimization.

The systems engineering process involves iterative stages like requirements analysis, functional analysis, synthesis, and verification. This approach is applied in various industrial settings, including manufacturing, supply chain management, and product development, to solve complex problems and improve overall system performance.

Systems engineering definition and principles

Interdisciplinary approach and key principles

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• Systems engineering employs an interdisciplinary approach to design, implement, and manage complex systems throughout their lifecycle
• Holistic thinking emphasizes understanding interactions between system components and their environment
• Requirements management involves documenting and tracking system needs throughout development
• Lifecycle consideration accounts for all phases from concept to retirement
• Optimization focuses on overall system performance rather than individual components
• Emergent properties describe behaviors exhibited by the system as a whole, not present in individual parts
• Integration of technical and managerial aspects ensures successful system development and operation

Systems engineering process overview

• Iterative process includes concept development, engineering design, integration, verification, validation, and operation
• Requirements analysis identifies and documents stakeholder needs and system requirements
• Functional analysis breaks down system functions and allocates them to subsystems or components
• Synthesis combines components into a cohesive system design
• System verification confirms the system meets specified requirements
• System validation ensures the system fulfills its intended purpose in the operational environment

Systems engineering process in industry

Requirements and design phases

• Requirements elicitation involves stakeholder analysis and documentation of system needs
• Functional analysis and allocation assign system functions to subsystems or components
• System architecture development defines overall structure and relationships between elements
• Trade studies evaluate alternative designs based on criteria (cost, performance, reliability)
• Risk management identifies, assesses, and mitigates potential risks throughout the lifecycle

Implementation and evaluation phases

• System integration combines subsystems and components into a functioning whole
• Verification testing confirms system meets specified requirements
• Validation testing ensures system fulfills intended purpose in operational environment
• Operation and maintenance support system throughout its useful life
• System upgrades and modifications address changing requirements or improve performance

Industrial applications

• Manufacturing systems optimization (production lines, automation)
• Supply chain management (logistics, inventory control)
• Large-scale infrastructure development (transportation systems, power grids)
• Product development (consumer electronics, automotive design)
• Process improvement (quality control, efficiency enhancement)

Systems thinking for industrial problems

Holistic approach and key concepts

• Systems thinking focuses on understanding interconnections and relationships within complex systems
• Considers entire system context rather than isolated components when addressing problems
• Identifies leverage points where small changes lead to significant improvements
• Promotes consideration of long-term consequences and unintended side effects
• Encourages cross-functional collaboration and integration of diverse perspectives
• Aids in recognizing and managing emergent properties and behaviors

Systems thinking tools and techniques

• Causal loop diagrams visualize feedback relationships between system elements
• Stock-flow models represent accumulations and rates of change within systems
• System archetypes identify common patterns of behavior in complex systems
• Iceberg model explores underlying structures and mental models driving system behavior
• Soft systems methodology addresses ill-defined problems in human activity systems

Application to industrial problems

• Supply chain optimization (reducing bullwhip effect, improving inventory management)
• Manufacturing process improvement (identifying bottlenecks, reducing waste)
• Product lifecycle management (considering environmental impact, design for recyclability)
• Organizational change management (addressing resistance, fostering innovation)
• Energy systems planning (integrating renewable sources, improving grid resilience)

Systems engineering tools in practice

Requirements and design tools

• Requirements traceability matrices ensure all system requirements are met throughout development
• Quality Function Deployment (QFD) translates customer requirements into technical specifications
• Functional flow block diagrams illustrate system functions and their relationships
• N2 diagrams represent interfaces between system components
• Design structure matrices analyze dependencies and interactions in complex systems

Modeling and simulation techniques

• Computer-aided design (CAD) creates digital representations of system components and assemblies
• Finite element analysis (FEA) evaluates structural performance and stress distribution
• Discrete event simulation models system behavior and performance over time
• Agent-based modeling simulates interactions between autonomous entities within a system
• Monte Carlo simulation assesses risk and uncertainty in system performance

Analysis and evaluation tools

• Failure Modes and Effects Analysis (FMEA) identifies potential failure modes and their impacts
• Fault tree analysis determines root causes of system failures
• Reliability block diagrams model system reliability and availability
• Life cycle cost analysis evaluates total cost of ownership for system alternatives
• Decision matrix analysis compares design options based on multiple criteria

Project management and documentation

• Systems Engineering Management Plans (SEMPs) outline processes, methods, and tools for system development
• Work breakdown structures organize project tasks and deliverables
• Gantt charts schedule project activities and track progress
• Configuration management systems control changes to system design and documentation
• Technical performance measures track key system parameters throughout development