The current product and assembly processes of system development in the vehicle industry are characterised by a multitude of different model formats, a relatively low level of data integration, and an unsatisfactory management of information. This article presents an integrated design and assembly planning process which applies several model-to-model (M2M) transformations in order to ensure a seamless transition from product requirements to an assembly system layout and design. The digital process employs a framework based on graph-based design languages (GBDLs) and achieves an integration in a model-based systems engineering (MBSE) industrial context. The underlying hypothesis that this seamless transition is possible is tested on the basis of the product and assembly system development of a sports vehicle. In this article, a skateboard is used for detailing and explaining the different modelling perspectives throughout the engineering and assembly process of this product. Due to a conscious application of GBDLs in an MBSE framework, it is possible to achieve a continuous sequence of M2M transformations which guarantees a maximum level of information integrity. These two aspects are cornerstones for a future integrated design automation of a product and its assembly system. It is important to note that the presented approach is universal and can be used in the production of components for the automotive industry, entire vehicles, and their assembly.

Using a balancing scooter as an example, the development of an automated design process for a hybrid assembly system is illustrated. A framework of graph-based design languages is used for the modeling, starting with an ontology which defines the concepts and their relationships in Unified Modeling Language (UML) syntax. Based on this, a design graph is generated using a rule-based approach. Furthermore, the question of how manual assembly steps can be simulated and analysed as part of an automated design process is addressed. All processes are automatically derived on the basis of the product model and the associated joining information, which form the basis for a 2D- and 3D-layout of an assembly cell. The manual assembly system is evaluated via an Unreal Engine 5 interface using the created layout. The virtual execution of the assembly enables the recording of movement data, which serves as the basis for an economic simulation. The results of this simulation provide the foundation for continuous adaptation of the assembly system, ensuring that the assembly process is designed in accordance with economic principles. The architectural design allows for the validation of hybrid assembly systems in their developmental phase.

Current research is investigating strategies, methods, and tools aimed at making vehicles more fault-tolerant and resilient. However, one level of product concretization—the level of abstract physics—was not yet in the focus of the scientific discourse. As a consequence of an increasing complexity of technical systems, the approaches fault-tolerant design and resilient design become even more important and decisive product characteristics concern the level of abstract physics. The paper analyses opportunities and approaches on this level, which are intended to allow an accommodation of faults and/or to increase the resilience of vehicle systems. Four different areas of potential improvement were identified. A systematic procedure and a conscious integration in industrial vehicle development processes were investigated. The research results were developed in several current vehicle component development processes and are explained using this basis. The presented research intends to open a new field of investigation, consequently a main emphasis is directed to future research contents and directions.