Industry 4.0 is based on the digitization of manufacturing industries and has raised the prospect for substantial improvements in productivity, quality, and customer satisfaction. This digital transformation not only affects the way products are manufactured but also creates new opportunities for the design of products, processes, services, and systems. Unlike traditional design practices based on system-centric concepts, design for these new opportunities requires a holistic view of the human (stakeholder), artefact (product), and process (realization) dimensions of the design problem. In this paper we envision a “human-cyber-physical view of the systems realization ecosystem,” termed “Design Engineering 4.0 (DE4.0),” to reconceptualize how cyber and physical technologies can be seamlessly integrated to identify and fulfil customer needs and garner the benefits of Industry 4.0. In this paper, we review the evolution of Engineering Design in response to advances in several strategic areas including smart and connected products, end-to-end digital integration, customization and personalization, data-driven design, digital twins and intelligent design automation, extended supply chains and agile collaboration networks, open innovation, co-creation and crowdsourcing, product servitization and anything-as-a-service, and platformization for the sharing economy. We postulate that DE 4.0 will account for drivers such as Internet of Things, Internet of People, Internet of Services, and Internet of Commerce to deliver on the promise of Industry 4.0 effectively and efficiently. Further, we identify key issues to be addressed in DE 4.0 and engage the design research community on the challenges that the future holds.

A material's design revolution is underway with a focus to design the material microstructure and processing paths to achieve certain performance requirements of products. A host of manufacturing processes are involved in producing a product. The processing carried out in each process influences its final properties. To couple the material processing-structure-property-performance (PSPP) spaces, models of specific manufacturing processes must be enhanced and integrated using multiscale modeling techniques (vertical integration) and then the input and output of the various manufacturing processes must be integrated to facilitate the flow of information from one process to another (horizontal integration). Together vertical and horizontal integration allows for the decision-based design exploration of the manufacturing process chain in an inverse manner to realize the end product. In this paper, we present an inverse method to achieve the integrated design exploration of materials, products, and manufacturing processes through the vertical and horizontal integration of models. The method is supported by the concept exploration framework (CEF) to systematically explore design alternatives and generate satisficing design solutions. The efficacy of the method is illustrated for a hot rod rolling (HRR) and cooling process chain problem by exploring the processing paths and microstructure in an inverse manner to produce a rod with specific mechanical properties. The proposed method and the exploration framework are generic and support the integrated decision-based design exploration of a process chain to realize an end product by tailoring material microstructures and processing paths.

The steel manufacturing process is characterized by the requirement of expeditious development of high quality products at low cost through the effective use of available resources. Identifying solutions that meet the conflicting commercially imperative goals of such process chains is hard using traditional search techniques. The complexity in such a problem increases due to the presence of a large number of design variables, constraints and bounds, conflicting goals and the complex sequential relationships of the different stages of manufacturing. A classic example of such a manufacturing problem is the design of a rolling system for manufacturing a steel rod. This is a sequential process in which information flows from first rolling stage/pass to the last rolling pass and the decisions made at first pass influence the decisions that are made at the later passes. In this context, we define horizontal integration as the facilitation of information flow from one stage to another thereby establishing the integration of manufacturing stages to realize the end product. In this paper, we present an inverse design method based on well-established empirical models and response surface models developed through simulation experiments (finite-element based) along with the compromise decision support problem (cDSP) construct to support integrated information flow across different stages of a multistage hot rod rolling system. The method is goal-oriented because the design decisions are first made based on the end requirements identified for the process at the last rolling pass and these decisions are then passed to the preceding rolling passes following the sequential order in an inverse manner to design the entire rolling process chain to achieve the horizontal integration of stages. We illustrate the efficacy of the method by carrying out the design of a multistage rolling system. We formulate the cDSP for the second and fourth pass of a four pass rolling chain. The stages are designed by sequentially passing the design information obtained after exercising the cDSP for the last pass for different scenarios and identifying the best combination of design variables that satisfies the conflicting goals. The cDSP for the second pass helps in integrated information flow from fourth to first pass and in meeting specified goals imposed by the fourth and third passes. The end goals identified for this problem for the fourth pass are minimization of ovality (quality) of rod, maximization of throughput (productivity), and minimization of rolling load (performance and cost). The method can be instantiated for other multistage manufacturing processes such as the steel making process chain having several unit operations.

A power grid is vulnerable and failures are inevitable. Failures decrease the power supply with an adverse effect on meeting the demand for electricity. Therefore, there is a need for a method to design power grid networks that result in the least possible disruption to the power supply when a failure occurs. In the literature, the focus has been on the design of the generation system without considering the transmission system or failures in the transmission system. Since power grids are integrated generation and transmission systems, each system will affect the other, so both generation and transmission systems need to be considered, as they are in this article. Methods developed for the structural modelling and analysis of supply chains are shown to be useful. The focus in this article is on describing a method using the supply chain construct for designing power grids that are relatively insensitive to failure in the integrated generation and transmission system. The efficacy of the method is illustrated using data from the Tehran Regional Electric Company. One of the findings is that targeted failures have a higher impact on decreasing the performance of the power grid than random failures. However, the focus is on the method rather than the results per se.

In this paper, we extend our previous work on a goal-oriented inverse design method to carry out inverse robust design by managing the uncertainty involved. The extension embodies the introduction of specific robust design goals and new robust solution constraints anchored in the mathematical constructs of Error Margin Indices (EMIs) and Design Capability Indices (DCIs) to determine “satisficing” robust design specifications across analytical model-based process chains. Contributions in this paper include the designer’s ability to explore satisficing robust solution regions when multiple conflicting goals and multiple sources of uncertainty are present. Using the goal-oriented inverse design method, robust solutions are propagated in an inverse manner. We demonstrate the efficacy of the method and the associated robust design functionalities using an industry-inspired hot rolling and cooling process chain example problem for the production of a steel rod. In this example, we showcase the formulation of multiple mechanical property goals for the end product using the robustness metrics and the exploration of satisficing robust solutions for material microstructure after the cooling process using the robust solution constraints. The robust solutions thus identified are communicated in an inverse manner using the design method to explore satisficing robust solutions for the microstructure generated after the hot rolling process. Using the example, we demonstrate the robust co-design of material, product, and associated manufacturing processes. The method and the associated design constructs are generic and support the formulation and inverse robust design exploration under uncertainty of similar problems involving a sequential, analytical model-based flow of information across process chains.