With software and control systems becoming standard fare even in what used to be considered straight mechanical-based products, model-based design -- an engineering approach rooted in industries like aerospace and defense -- is gaining traction as companies seek ways to reduce the growing complexity of development while reducing time-to-market.
In traditional development processes, engineers gather requirements from multiple sources, create a paper specification, and then work off that paper spec to produce a detailed design concept. The concept is then prototyped using simulation or physical hardware, and it is continually checked against requirements until a suitable design is achieved. Testing typically occurs toward the end of this multistage process -- a design workflow that can be problematic if errors or flaws are detected late in the game, when they are far more costly to remedy.
Using The MathWorks tools for model-based design, CCM created a custom controller that increased the repeatability of :Dotrix Modular printers for its customer, Agfa.
In contrast, with the model-based design approach, a system model serves as the centerpiece of the development process, starting as early as the requirements phase and evolving through design, implementation, and testing. This single model is an executable specification that can be linked to the original requirements. The approach allows for two-way traceability between the design and the requirements while enabling a multidomain engineering team to provide continual input and refine the model throughout the development process. Simulation is employed every step of the way to determine whether the model is behaving as desired.
The MathWorks, which markets one of the leading tools for model-based design, says the practice was originally tuned for the development of dynamic systems such as control systems, signal processing, and communications systems but is systematically being embraced by other industry segments grappling with complexity issues.
"Software complexity is the big driver," says Ken Karnofsky, senior strategist for signal processing applications at The MathWorks.
Model-based design first took hold in the automotive, aerospace and other industries dealing with extremely complex, large-scale embedded applications that needed a lot of process rigor beyond some of the ad hoc engineering happening in other segments, he said. Other fields, like industrial machinery and medical communications, are now facing similar requirements, which are prompting a recasting of traditional design approaches in the hopes of finding a more efficient way.
Jon, I don't think I could have said it better (in fact, I know I couldn't). You really just described the biggest hurdle to model-based design. Because it's an entirely new way of thinking and because it requires a completely different mentality of cross-functional collaboration, there will ultimately be push-back from engineers who don't thoroughly understand the benefits and are reticent to make any kind of change.
To embrace this on a grand scale throughout an engineering organization will require a robust change management effort and as you mention, a champion. Bringing in model-based design tools on a piecemeal basis won't be enough to foster any kind of sweeping process change.
Thanks, Beth. Here's a book I recommend highly, "Driving Technical Change; Why People on Your Team Don't Act on Good Ideas, and How to Convince Them They Should," by Terrency Ryan, published by The Pragmatic Bookshelf. The author describes the types of people we typically find on a team, from the uninformed and the herd to the cynics and irrationals, and he explains how to work with them and get them on-board with new tools and techniques. (OK, you can't convince the irrational people.) Although the book used programmers for its examples, the information applies equally well to engineers who should adopt model-basded design. At 128 pages, the book is easy to read in one evening.
John and Beth are correct about the challenge of embracing Model-Based Design for developing embedded systems. My own experience is that companies gradually adopt, usually starting with control system engineers. The progression is usually multiyear, beginning with desktop simulation, moving to real-time testing and validation, and ending with code generation for production systems. This approach provides increasing value at each stage, can be woven into existing design practices, and avoids the unwanted shock of a complete change to a development process. Industries are in different stages of Model-Based Design adoption. The Aerospace and Automotive industries are leaders, primarily because their software systems are very complex. In 2010, Design News discussed, http://www.designnews.com/document.asp?doc_id=229640, how the Automotive industry is adopting Model-Based Design. Within the industrial markets, automation suppliers developing motor controls and power backups, and solar and wind energy companies developing renewal energy sources are the furthest along the path. As my colleague Ken Karnofsky said in the article, "Software complexity is the big driver." But we are seeing more interest from the traditional machine builders. Recently an engineer with whom I was meeting pointed out that it is the software that running in machines that is becoming more complex, not only the hardware.
Thanks for the perspective, Tony, and a great description for how the adoption tends to unfold within organizations. Jon: Thanks for the recommendation on a book for change management. Whether it's about leading a culture of model-based design or some other type of major process change, I imagine there are some good takeaways for overcoming resistance.
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