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System Lifecycle Management: Initial Approach for a Sustainable Product

Development Process Based on Methods of Model Based Systems Engineering

Conference Paper in IFIP Advances in Information and Communication Technology · July 2014
DOI: 10.1007/978-3-662-45937-9_29

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 System Lifecycle Management:
Initial Approach for a Sustainable Product Development
Process Based on Methods of Model Based Systems
Engineering

Martin Eigner1, Thomas Dickopf1, Hristo Apostolov1, Patrick Schaefer1,

Karl-Gerhard Faißt1, Alexander Keßler1,
1
Institute for Virtual Product Engineering, University of Kaiserslautern, Germany
1
[email protected]

Abstract. Modeling today’s products means modeling interdisciplinary

‘product systems’ integrating various authoring systems with the technical-
administrative product structure and the related processes. Achieving
sustainability of the stated product systems, yields new artifacts, expanding the
area to be considered and impedes traceability. This paper introduces System
Lifecycle Management as key concept. Along with an approach based on
methods of Model Based Systems Engineering the outlined problems are solved
on an exemplary sustainable development process. The paper defines a
framework for modeling the product system in the early development phases,
which accompanies system design considering sustainability aspects in a
prospective view. To demonstrate the proposed method, the paper focuses on
expanding existing modeling constructs by relevant behavior elements
capturing semantic links and information. First analyses and capabilities of the
approach are presented in a case study of a wheeled excavator.
Keywords: System Lifecycle Management, Model Based Systems
Engineering, Sustainability, Traceability.

1 Introduction

Contemporary technological products are multi-disciplinary systems developed by

multiple engineering disciplines. The risen requirements on these systems led to a
complexity explosion, especially with regard to the information flow within the
product development process [1]. As a result of new upcoming legislation focusing on
sustainability, complexity is increasing furthermore [2]. But, in parallel to the
challenges arising, great opportunities are also evolving for manufacturing companies
to make their contribution to the sustainability paradigm and to gain advantage over
their competitors through ecologically, economically and socially motivated system
and process innovations [3] [4]. A multi-disciplinary system development requires a
rethinking of common methods, processes, IT solutions and organizational forms as
known in product development today. To cope with complexity and to assure

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fulfillment of new requirements, traceability throughout the entire system lifecycle is

needed. Today, traceability in a Product Lifecycle Management [1] [5] solution
manifests itself only in relations defined between product requirements and elements
of the bill of material.
This paper considers System Lifecycle Management [6] as a key concept for the
definition of engineering design processes. Model Based Systems Engineering [6] [7],
as essential part of the System Lifecycle Management concept, is a multi-disciplinary
engineering paradigm to guide the design process in the early phases and to achieve
traceability [8]. In this paper a new approach for a comprehensive system description
based on an extended V-Model [9] is presented. It constitutes a promising new
instrument for functional system description assisting to achieve a multi-disciplinary
system development taking into account the environmental aspect of sustainability.
The model builds on work of the ERMA research project [10], which aims at
proactive estimation of the eco-performance of future concepts of wheeled
excavators.

2 Motivation and Objective

In the field of construction equipment, with well-established, mechanical,

hydraulic, hybrid and electronic solutions, the need of eco-design will raise
significantly because of further increase of energy costs, stricter energetic
requirements and growing competitive pressure. The prospective view within ERMA
[10] requires analysis of the wheeled excavator and the application of Life Cycle
Assessment [11] [12] in a proactive manner supporting the product development.
Table 1. Key Drivers of Environmental Impact.
Lifecycle Phase Environmental Impact Parameter
Production Raw Material Extraction
Manufacturing Processes
Operation Usage, Maintenance, Energy Consumption
Replacement of Spare Parts and Fluids
Recycling Recycling, Disposal,
Includes all Waste from Maintenance

Extensive concepts and new structures, such as innovative and integrated technical
solutions for increasing the total energy efficiency, are needed [13]. New
requirements on the product’s sustainability and eco-performance as well as the
demand for high flexibility lead to complex product systems which contain mechanic,
hydraulic, electric and even hybrid subsystems [14]. Systems like the investigated
wheeled excavator are characterized by a large number of constituent parts, complex
processes and, referring to the lifecycle, a dominance of the usage phase due to high
energy consumption throughout a long lifecycle [15] [16]. The overall effect of
energy and resource reduction through new technical concepts is often hard to predict,
especially in the case of multi-disciplinary systems. To quantify these predictions is
even harder. This leads to the need for a comprehensive system solution [17].

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 The results shown in figure 1 are based on an exemplary product structure, related
manufacturing, transportation and distribution processes as well as an assumption for
the usage phase. Regarding the lifecycle of a commercial vehicle, more than 90% of
the greenhouse gas emissions are resulting from energy consumption out of the usage
phase.

Fig. 1. Environmental Impact (Example: Greenhouse Gas Emission)

Regarding the Lifecycle of a Commercial Vehicle (adapted from [18]).

The paper is limited to the consideration of the usage phase as main driver of the
environmental impact. It deals with the outlined problem of an early system
description based on a dynamic view referring to specific behavior artifacts using the
example of greenhouse gas emissions. Challenges for a sustainable development
process are:

(a) Multi-disciplinary View on Complex Product Systems:

Current development processes of complex mechatronic products are heavily
influenced by multiple disciplines like mechanic, electronic and informatics as well as
dependencies between information elements and engineered system parts. System
specification, modeling and first simulations are still discipline-specific.

(b) Lifecycle View on Complex Product Systems:

Beside the assessment of the used materials based on the product structure, a
comprehensive consideration of all related processes, starting from raw material
extraction to the end-of-life activities as well as all supporting processes like
transportation, are of central importance in regard to sustainability.

An approach based on methods of Model Based Systems Engineering can help to

improve traceability within complex multi-disciplinary systems throughout multiple
lifecycle phases and thereby to identify key areas to be targeted by an exemplary case
scenario of the sustainable development process of a product system.

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3 Related Work

To enable an early system description, the new concept of System Lifecycle

Management, with a proposed extension on the V-Model within, is a promising new
instrument for functional description of a product system. In order to introduce an
approach for exemplary sustainable product development process, the theses that are
described in this paper build upon the previous work on sustainability assessment [2]
[3] [19] [20] [21] [22] [23] [24] and research on the topic of Model Based Systems
Engineering performed at the Institute for Virtual Product Engineering (University of
Kaiserslautern, Germany) [8] [25] [26] [27].

3.1 System Lifecycle Management

Up to 80% of the essential characteristics of each system are determined in the

early phase of its development [1]. Decisions made here are fundamental for the
entire lifecycle of the product system. Revising the system or changing processes in
later phases causes great effort. System Lifecycle Management represents a concept
rather than a monolithic IT system. Similar to Product Lifecycle Management [3] [5]
[20] [23], System Lifecycle Management [6] [29] is an integrated, information-driven
concept to improve the performance of a product system over the entire lifecycle. It
achieves efficiency by using a shared information core system that helps engineers to
efficiently manage complexity in the lifecycle of the product system from first
definition of requirements to end-of-life activities. Thus, the concept does not provide
innovative systems but can contribute to engineering at administrative level (see
figure 2) by providing the right information at the right time in the right context.

Fig. 2. Two-Layer-Model of System Lifecycle Management (adapted from [6] and [7]).

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 Definition: System Lifecycle Management (SysLM) is a general information
management solution extending today’s Product Lifecycle Management to the
early phase and all disciplines including services. The concept is based on the
direct or indirect (via TDM1) integration of various authoring systems along the
system lifecycle with the technical-administrative backbone for system or
product models and processes. All development phases and the resulting models
(R,F,L,P, … 2) of the system’s lifecycle are included and connected to achieve
traceability.
As an exemplary extension to Product Lifecycle Management in regard to eco-
design and sustainability [1] [3] [30] [31] [32], System Lifecycle Management can
help to improve the environmental and sustainability performance of a product system
by achieving traceability with regard to the material flow, starting from extraction of
raw materials, processing, production, manufacturing, storage, transport, usage and
disposal. In addition, requirements traceability is realized over the entire development
process. Within, the concept of Model Based Systems Engineering provides methods
to guide the cross-disciplinary, virtual product development process and to achieve
the required traceability.

3.2 Model Based Systems Engineering

Model Based Systems Engineering (MBSE) is a multi-disciplinary engineering

paradigm propagating the use of models instead of documents to support analysis,
specification, design and verification of the system being developed [33]. Systems
Engineering as such, comprises technical but also management processes to generate
a balanced system solution in regard to various stakeholder needs and to reduce risks
that can hinder the success of a project [34]. In the case of sustainability, this could be
an early consideration of the usage phase. In the study introduced in this paper, by
using models instead of documents, a discipline-neutral view of the system
specification is created. The resulting coherent system model helps to understand and
to overview the complexity of the developed system and, moreover, it simplifies the
communication in a multi-disciplinary development team. Interdependencies between
individual system components are managed; the system is kept consistent to the
specification and satisfies all defined requirements. In this context, requirements
traceability can be archived over the entire development process. In previous work
done at the Institute for Virtual Product Engineering [25] [26], a methodical guideline
for the use of the Model Based Systems Engineering paradigm has been developed
and conceptually realized by extending the V-Model from [9].
With regard to the V-Model, the extended version (see figure 3) enables a model-
based and structured system description on the left wing of the ‘V’ in the early design
phases. The systemization on the left wing of the V-Model is used to describe the
three levels of specification, first simulation and discipline-specific modeling. Parallel
to these overlapping levels, the information artifacts or model elements are

1 Team Data Management (TDM): Authoring tool-close (local) management system for a development
team, regardless of the PLM backbone.
2 Requirement, Function, Logical System Element, Physical Part, etc. (R, F, L, P, …): Defines information
artifacts out of system or product model within the development process.

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The IFIP WG5.1 11th International Conference on Product Lifecycle Management – PLM14

differentiated in requirements (R), functions (F), logical solution elements (L) and
physical parts (P), which are modeled in authoring tools and languages.

Fig. 3. Extended V-Model for Multi-Disciplinary Product Development

(based on VDI 2206 [9], adapted from [25][26]).
Through semantic links between different model elements, as well as between
elements of the same type, traceability could be ensured from a ‘horizontal’ and
‘vertical’ point of view. ‘Vertical’ traceability is to be guaranteed by linking system
elements hierarchically above different system levels. The allocation links between
different model types (R-F-L-P) permit ‘horizontal’ traceability over the different
system specification stages [25]. New in this context is the consideration of behavior
(B) within the system development. The behavior of the system and the user's
behavior have high impact on the regarded eco-performance.
System models are created by application of the Systems Modeling Language
(SysML). In addition, a specific data scheme describes and defines these elements as
well as the semantic links between them. Furthermore, it allows integrating and
managing the information in a System Lifecycle Management (SysLM) backbone.

4 Approach

Several solutions for sustainability assessment of product systems have been

developed [21] [23] [35] [36] but the subject is still not solved satisfactory. None of
these solutions considers both of the introduced challenges in one joint and integrated
approach. Following, an initial approach for an exemplary sustainable product
development process based on methods of Model Based Systems Engineering is
introduced.

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4.1 Methodology to Include Behavior in the Early Development Phases

The V-Model from VDI 2206 [8] defines a systematic methodology for developing
mechatronic systems, but it is not addressing all aspects of model-based design. This
gap between requirements engineering and the intellectual model of the product
system has been closed by research [6] [7] [25] [26] within the RFLP-approach and
the three layers of modeling and specification, specification and first simulation as
well as discipline specific modeling on the left wing of the V-Model. However, the V-
Model is not suited to model and maintain behavior such as the usage phase of a
product system. An approach for the extension of the V-Model is depicted in figure 3.
The following steps describe the procedure of modeling behavior in the early
design phases:

Step 1 - Identification of Key Drivers Following the RFLP Approach:

In the first step the occurring gap between requirements and physical parts has to
be closed. The outcoming traceability of structural elements along RFLP helps to
identify the key drivers at an early level of development.

Step 2 - Specification of Behavior Artifacts in the Early Phase:

Corresponding to the ‘horizontal’ traceability of structural elements in step 1, a
‘horizontal’ traceability of behavioral artifacts has to be specified, which allows a
quantitative consideration of behavior from an abstract view at requirements level to a
concrete description on the level of logical elements. Thereby, the identified key
drivers from step 1 could be observed in the context of their main functions.

Step 3 - Analysis of Behavior Artifacts in the Early Phase:

For a first calculation and simulation of system’s behaviors in the early phases of
development, it is needful to generate an analysis context which describes the subset
of elements that are needed as well as their relationships through constraints and
properties.

Step 4 - Requirement Traceability, Verification and Validation:

Based on the previous steps, with the help of specific simulation and calculation
tools the developed system model has to be verified and validated against the
requirements. The procedure takes place in iterative loops.

Step 5 - Interpretation and Visualization of the Results:

In this step, the interpretation and visualization of the results are carried out.
Concrete recommendations for decisions have to be derived from it.

4.2 Case Study: Modeling Behavior in an Exemplary System Model

The specification of the system, modeled by structure elements in the early phase is
too coarse for a detailed assessment which can support the engineering eco-design. It
is important to take the usage phase into account already in the early design phase and
to provide traceability between the requirements of the product (see figure 4: R-level)

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The IFIP WG5.1 11th International Conference on Product Lifecycle Management – PLM14

and the product’s physical elements (see figure 4: P-level). Based on an abstract
example for the modification of an environmental constraint, it will be shown how it
is possible and helpful to consider the requirements derived from the usage phase of a
working machine, or a similar product, already in the early phases of development by
using Model Based Systems Engineering.

Problem description: The greenhouse gas emission for a working machine, e.g. in
Japan, should be lowered to a maximum average value of 1.000 t CO2-eq. (based on
the results of figure 1 in our example we limit the accruement of the greenhouse gas
emission only on the usage phase).

Step 1 – Identification of Key Drivers Following the RFLP Approach:

At the example of changed requirement on the allowed average CO 2-equivalent
emissions of the machine, the traceability provided by the presented approach will
help to identify the engine, for example, as a key driver at the logical system level.
Figure 4 describes the context schematically.

Fig. 4. Schematic Representation of the Identification of Key Drivers through

Traceability along RFLP (adapted from [25]).
Step 2 - Specification of Behavior Artifacts in the Early Phase:
Since the engine as an assembly is not of big importance for the environmental
impact, rather a quantitative consideration of working behavior, energy consumption
and thereof resulting emissions has to be taken as a basis. The mainly used
functionalities have to be modeled at the beginning of the specification and to be
considered referring to the design of the machine for specific markets.
The Systems Modeling Language (SysML) allows describing these major
functions in an abstract way with the help of the use case diagram. It illustrate how
the system is used to achieve the goals, set by its users, and with which elements it
interacts during operation. These could be people, other systems or the environment
[33]. Based on the example of the wheeled excavator (see chapter 2), the lower right
part of figure 5 shows the main use case scenarios according to a test method for
energy consumption of hydraulic excavators [37], here modeled in SysML. One
possible way to define these use case scenarios in SysML is to associate them with
activities in a block context including relevant properties as parameter elements [38].
Activities in SysML describe behaviors performed by specific parts of a system or
their components over the entire lifecycle [33]. The relations between different model
elements (see figure 5) in the system are described through allocation relationships. In
regard to the further use of the defined parameter properties, it is important to

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differentiate their types in the SysML model. The parameter properties might be
based on a specification (such as a limitation through a requirement) or on a
prediction (such as results from simulations or conclusions from field data).

Fig. 5. Setting of Use Cases and their Parameters Referring to Logical Solution Elements.

Within the considered situation of usage cycles of a wheeled excavator, a running

time of 15.000 hours is supposed to be a specification property as well as a new
limitation rate for a greenhouse gas emission lower than 1.000 t CO2-eq. A prediction
property is represented in this case by the simulated value.

Step 3 - Analysis of Behavior Artifacts in the Early Phase:

To simulate or calculate the emission values of the different use cases or,
respectively, the emission of the whole wheeled excavator in regard to its usage,
SysML allows generating a first specification of a simulation through different
diagrams. With the help of a block definition diagram it is possible to determine the
context of an analysis (see figure 6). Blocks of the system which are utilized in this
context are linked to the analysis block by associations. These blocks provide the
parameters that are used for the analysis and a placeholder for prediction properties

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The IFIP WG5.1 11th International Conference on Product Lifecycle Management – PLM14

which represent the outcoming results. The current calculation is described by

different constraints. These constraints are connected to the analysis context element
through a composite association.

Fig. 6. Definition of an Analysis Context for the Greenhouse Gas Emission

of a Wheeled Excavator.
With the help of the SysML parametric diagram the relationship between the
different model elements of the analysis context can be described through their
parameters and specified constraints [38]. Figure 7 clarifies the mathematical
progression for the calculation of the greenhouse gas emissions of the whole wheeled
excavator, as well as separately for the different use case scenarios. Additionally the
constraint block ‘compare’ checks if the current value satisfies the given requirement.
Based on the information of this diagram and the structural system description, test
cases can be generated and executed by specific calculation and simulation tools.

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 Fig. 7. Parameter Relations for the Analysis of Greenhouse Gas Emission.

Step 4 - Requirement Traceability, Verification and Validation:

In the current example, a need for action on the system’s L-level can result from
the changed requirement on the average CO2-eq. emissions and the engine has been
tracked down as main driver of the impact. Considering the machine’s behavior over
its lifetime (see table 2) assuming the following localized working-cycle distribution:
Table 2. Exemplary Working Cycle Distribution of an Excavator (according to [37]).

Working Cycle Grading Trenching Lifting Traveling Idling

Percent of life time 25% 25% 10% 17% 23%

Fuel consumption, kg/h 34 30 26 31 8

Arising from a machine lifetime of 15.000 hours of operating service the following
values for greenhouse gas emission as shown in table 3 are the results of this
calculation.

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The IFIP WG5.1 11th International Conference on Product Lifecycle Management – PLM14

Table 3. Results from the Calculation in Different Working Cycles

Working Cycle Grading Trenching Lifting Traveling Idling

CO2-eq. Emission 340,4 t 300,4 t 104,1 t 211,2 t 73,7 t

Total 1029,3 t

In regard to the result and with the help of the SysML model it is possible to trace
the value to concrete components, functional and logical elements and thereby realize
most suitable fields of action. Furthermore new requirements based on this specific
working cycles could be added.
Step 5 - Interpretation and Visualization of the Results:
In the current example and based on the results, the implementation of a start-stop
system for a reduction of the time spent in idling would improve the system as well as
optimizing the drive train. Otherwise alternative concepts could be creating on the F-
level to improve the systems layout.
Table 3. Variation referring to the Calculation in Different Working Cycles

Working Cycle Grading Trenching Lifting Traveling Idling

Life time in hours 3.750 3.750 1.500 2.550 1.050

CO2-eq. Emission 340,4 t 300,4 t 104,1 t 211,2 t 22,4 t

Total 978,5 t

Last but not least, this information has to be visualized in an easy to interpret way
and supplied to decision-makers. An appropriate integration of the proposed behavior
artifacts and of a general behavior description into the System Lifecycle Management
backbone is part of further research.

5. Conclusion and Outlook

Modeling a complex product system requires the integration of various authoring

systems and the product structure with related processes. Following this way, full
traceability can be achieved. The paper introduced System Lifecycle Management as
key concept integrating the introduced two layers. The proposed approach which is
based on methods of Model Based Systems Engineering addresses exemplarily one
specific outlined problem of a sustainable development process of a product system.
The paper reuses and adapts existing modeling constructs for capturing relevant
behavior artifacts at the example of the usage phase of a wheeled excavator. Semantic
links are formalized between early definition phase and first prediction in form of
constraint blocks regarding sustainable product development. For the future, the
implementation of the introduced approach will be provided within a System
Lifecycle Management backbone. To give the user the capability to trace the impact
of design decisions easily, an intuitive and graphically rich user interface will be
implemented on top of the System Lifecycle Management backbone.

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Acknowledgments. The authors would like to acknowledge funding from the
German Bundesministerium für Bildung und Forschung attended by PTKA for
research of mecPro2 and from Stiftung Rheinland-Pfalz für Innovation for research of
ERMA. The authors would like to thank Torsten Gilz and Radoslav Zafirov for their
contribution and research on the topic of Model Based Systems Engineering, for their
input and assistance.

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