Available online at www.sciencedirect.

com
Available online at www.sciencedirect.com

Available ScienceDirect
ScienceDirect
online atonline
Available www.sciencedirect.com
at www.sciencedirect.com

ScienceDirect
Procedia CIRP 00 (2019) 000–000
Procedia
ScienceDirect
CIRP 00 (2019) 000–000
www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia Procedia
CIRP 00 CIRP
(2017)100
000–000
(2021) 253–258
www.elsevier.com/locate/procedia

31st CIRP Design Conference 2021 (CIRP Design 2021)

31st CIRP Design Conference 2021 (CIRP Design 2021)
V-model
28th CIRP based
V-model based development
Design Conference, May 2018,of
development cyber-physical
ofNantes, France
cyber-physical
systems
systems and and cyber-physical
cyber-physical production
production systems
systemsarchitecture of
A new methodology to analyze the functional and physical
existing products foraa,, an
Iris Gräßler
Iris Gräßler assembly
Dominik
Dominik
Wiecheloriented
a*
productaa,,family
, Daniel Roesmann
Wiechela*, Daniel Roesmann identification
Henrik Thiele
Henrik Thiele
a
a
Heinz-Nixdorf-Institute, Paderborn University, Fuerstenallee 11, Paderborn, 33102, Germany
a

Heinz-Nixdorf-Institute, Paderborn University, Fuerstenallee 11, Paderborn, 33102, Germany

a

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat

* Corresponding author. Tel.: +49-5251 60-6264 fax: +49-5251 60-6280. E-mail address: dominik.wiechel@hni.upb.de
* Corresponding author. Tel.: +49-5251 60-6264 fax: +49-5251 60-6280. E-mail address: dominik.wiechel@hni.upb.de
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Challenges of the development of mechatronic systems and corresponding production systems have increased steadily. Changes are primarily
Challenges of theproduct
due to increased development
complexityof mechatronic systemstoand
and the connection the corresponding
internet of thingsproduction
and services,systems have Cyber-Physical
enabling increased steadily. Changes
Systems (CPS)areand
primarily
Cyber-
due to increased product complexity and the connection to the internet of things and services, enabling Cyber-Physical
Physical Production Systems (CPPS). Major innovations of the revised VDI guideline 2206 for developing mechatronic systems are systems Systems (CPS) and Cyber-
Physical
Abstract
thinking asProduction Systems
a core element and(CPPS). Major innovations
six checkpoints for structuringof the revised VDI
deliverables guideline
along 2206 for
the V-Model. developing
These mechatronic
checkpoints serve forsystems are in
orientation systems
result
thinking as a core element and six checkpoints for structuring deliverables along the V-Model. These
progress and thus enable a structured and complete development process. However, tasks and checkpoints of the new guideline focus on checkpoints serve for orientation in result
the
Inprogress and thus enable
today’sdevelopment
product business itselfa without
structured
environment, and towards
theintegrating
trend complete development
more
the development process.
productofvariety
relatedand However, tasksoptimization
customization
CPPS, enabling and checkpoints
is unbroken. Dueoftothe
thisnew
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system development. of
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products
contributes optimization
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families.
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Implications
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productprovide
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aredevelopers
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the aim to
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analyze
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on thedevelopment
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Different
steps support for
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and evaluate system
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maturity developers
however, of CPPS
may differ
of the whole, for CPS
largely
integrated by enabling the
in terms of the number
development. project
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© 2021 to check
ofThe
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This fact
Published impedes
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Elsevier development
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efficient steps andand
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product integrated development.
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© 2021
© 2021 The
The Authors.
Authors. Published
Published by
by Elsevier
Elsevier Ltd.
Ltd. existing
This
This is
system. an
is A open
annew access
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openmethodology articleisunder
proposed
under the
the CC BY-NC-ND
to analyze
CC BY-NC-ND license
license (https://creativecommons.org/licenses/by-nc-nd/4.0)
products in view of their functional and physical architecture. The aim is to cluster
(https://creativecommons.org/licenses/by-nc-nd/4.0)
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these is an
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the 31st CIRP
optimization Design
of existingConference
assembly 2021
lines and the creation of future reconfigurable
Peer-review
Peer-review under responsibility
under responsibility of the scientific
of System
the scientific committee of the
committee Product 31st CIRP
of the 31st CIRPDesign Conference
Design Conference 2021.
2021
Keywords:
assembly Cyber-Physical
systems. Based on Production
Datum Flow (CPPS);
Chain, theV-Model;
physical structure System Development;
of the products isIntegrated
analyzed.Development;
Functional VDI 2206
subassemblies are identified, and
Keywords: Cyber-Physical Production System (CPPS); V-Model; Product System Development; Integrated Development; VDI 2206
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
1. Introduction
example of a nail-clipper is used to explain the proposed methodology. Ansuch such as simultaneous
industrial engineering
case study onengineering have
two product have
familiesgained in importance
of steering columns of in
1. Introduction
thyssenkrupp Presta France is then carried out to give a first industrial evaluation recentasof
simultaneous
years. Therefore,
the proposed an extension of gained
approach.
in importance
the guideline to includein
recent
aspectsyears.
of theTherefore,
integratedan extension ofofthe
development CPSguideline
and CPPS to include
would
© 2017TheThe Authors. Published
increasing complexity by Elsevier B.V. leads to rising
of products
The increasing
Peer-review under complexity
responsibility of the ofscientific
products leads to
committee rising
of to
the 28th CIRP aspects
offer of the integrated
highConference
Design potential to development of CPS and CPPS
increase the application of the method.
2018. would
demands on product development. The connection the
demands offer high potential to increase the application of theis:method.
internet ofon product
things development.
and services enablesThe cyberconnection to the
physical systems Therefore, the research question of this paper Which
internet
Keywords:
(CPS) and of thingsphysical
Assembly;
cyber and services
Design method; enables
production cyber physical
Family identification
systems systems
(CPPS). Existing implications must be transferred to the checkpointsis:of Which
Therefore, the research question of this paper the V-
(CPS) and cyber implications
for themust be transferred to the checkpoints of the V-
approaches needphysical
to be production
revised andsystems adapted (CPPS). Existing
to increasing model integrated development of CPS and CPPS?
approaches needVDI to be revised2206 and andadapted to increasing model
To for the integrated
answer the research development
question, ofa CPS and CPPS?
literature analysis to
challenges. The guideline its V-Model, as a
challenges. The VDI guideline 2206 andsystems, its V-Model, as a To
identifyanswer
relevant the research
information question,
at each a literature
checkpoint is analysis
performed. to
method
1.method for
Introduction developing mechatronic was first of the product range and characteristics manufactured and/or
identify relevant information at each checkpoint is performed.
publishedfor developing
in 2004. Since 2015, mechatronic
the guideline systems,
has been was first
updated The resulting
assembled information
in this system. In is this
transformed
context, into control
the main questions
challenge in
published in 2004. Since 2015, the guideline has been updated The subsequently
and resulting information
applied. is transformed into control questions
byDue
VDI GMA to Technical
the fast Committee
development (TC)in 4.10
the to adapt
domain the V-
of modelling and analysis is now not only to cope with single
by VDItoGMA Technical Committee (TC) 4.10 to adapt the V- and subsequently applied.
Model
communication specific andchallenges
an ongoing of CPS trenddevelopment.
of digitization Revision
and products, a limited product range or existing product families,
Model to specific
requirements included challenges of CPS
the introduction development.
of are
checkpoints, Revision
systems 2. State of the Art
digitalization,
requirements manufacturing
included enterprises
the introduction facing
of checkpoints, important
systems but also toofbe
2. State theable
Artto analyze and to compare products to define
engineering
challenges as
in a core
today’s element,
market requirements
environments: engineering
a as
continuing an new product families. It can be observed that classical existing
engineering
integral task as
ofaproduct
core element, requirements
development and theengineering
reduction asthe
of an 2.1. V-Model: from VDI 2206:2004 to VDI 2206:2020
tendency
integral towards reduction of product development times and product
2.1. families
V-Model: are
from regrouped
VDI 2206:2004 in function
to VDIof2206:2020
clients or features.
guidelinetask
shortened to aofmanageable
product
product development
lifecycles. page
In count and
addition,
the reduction
[1].there
The checkpoints
is an
of the
increasingare However, assembly oriented product families are hardly to find.
guideline
designedofto to asupport
manageable page count
development and [1]. The management
project checkpoints are in The V-Model was first introduced by Boehm as a software
demand customization, being at the same time in a global On the product family level, products differ mainly in two
designed to support
terms of specific development
control questions and
about project
(interim)management
results. in
The development method [2] and later adapted to the as
The V-Model was first introduced by Boehm a software
development
competition
terms with
of specific competitors
controlonquestions all over the world.
about (interim)Compared This trend,
results. The main characteristics:
development method (i)
[2]the
and number
later of components
adapted to the and (ii)
development the
new guideline focuses product development. to of mechatronic systems by the VDI 2206:2004 [3]. The basic
which
new is inducing
guideline version, the
focuses on development from macro to micro type
of of components
mechatronic (e.g.
systems mechanical,
by the VDI electrical,
2206:2004 electronical).
[3]. The basic
the preceding
markets, resultsversion, theproduct
in diminished new lot development.
guideline
sizes due doestonot Compared to
explicitly
augmenting
principle of the V-Model is the decomposition of a system, the
Classical methodologies
the preceding the new guideline does not explicitly principle
discipline of the V-Model
specific developmentisconsidering mainly single
the decomposition
of sub-systemsof and
products
a system, the
integration
address
product the topic
varieties of production,
(high-volume although
to low-volume integrated approaches
production) [1]. or solitary, already existing product families analyze the
address the topic of production, although integrated approaches discipline specific development of sub-systems and integration
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify
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by Elsevier Ltd.in the existing causes difficulties regarding an efficient definition and
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under by Elsevier Ltd.
the CCtoBY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
production system, it is important have a precise knowledge comparison of different product families. Addressing this
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the 31st CIRP Design Conference 2021
Peer-review under responsibility of the scientific committee of the 31st CIRP Design Conference 2021
2212-8271 © 2021 The Authors. Published by Elsevier Ltd.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-reviewunder
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responsibility of the
of the scientific
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committee of28th
of the the CIRP
31st CIRP
DesignDesign Conference
Conference 2018. 2021.
10.1016/j.procir.2021.05.119
 254 Iris Gräßler et al. / Procedia CIRP 100 (2021) 253–258
2 Author name / Procedia CIRP 00 (2019) 000–000
with verification of system elements at the same system level
as they were specified [4]. Based on experiences from
industrial application and technological progress, a number of
further developments of the V-Model have been published ever
since [5]. For example, Bender's V-Model focuses on the
system, subsystem and component level [6], while the V-
Model of the INCOSE Handbook is reduced to the essential
steps in order to be adaptable to any context in systems
engineering [7]. For the first time, the US-Department of
Transportation integrates upstream and downstream product
life cycle phases in the form of wings against the background
of systems engineering aspects. Upstream product lifecycle
phases lead to the "V" and downstream phases follow on from
the "V" [8]. Eigner’s V-Model also extends VDI guideline
2206:2004, in particular with the functional product description
and the interface to Product Lifecycle Management [9].
In the revision of the guideline 2206 published by VDI in
2020, checkpoints were introduced to structure logical tasks in
developing complex and interconnected systems (see figure 1)
[1] as well as the integration of requirement management and
aspects of systems engineering. Each checkpoint is supported
by control questions. For example, the tasks of requirements
elicitation are concluded by the checkpoint “specification” and
the degree of maturity of the developed system can be checked
by answering the given questions [10].
Figure 1 V-model of the VDI 2206:2020 [1]
2.2. Methodologies for product system development
There are different methods to develop a production system.
A basic procedure often referred to is the six step REFA [11],
which has the objective to provide the planner with practical
assistance in the successful execution of the individual
planning stages. A holistic view of the system can be achieved,
involving people, technology, organization and information.
Analysis of the initial situation: Initially, the project team
is determined. The team conducts a situation analysis using
established methods and tools.
Concretization of the planning task: Next, the tasks are
defined. The objectives are divided into organizational,
technical, cost and personal goals and specified by individual
target criteria.
Rough planning of the production system: Based on
required production processes for manufacturing the product
portfolio, necessary workstations are determined. Alternative
solutions for these workstations are elaborated and the
requirements for the material flow and information flows
facilities are derived. Subsequently, a technical and economical
evaluation of the alternatives is carried out.
Detailed planning of the production system: The
specifications are determined and the subsystems of the
production systems are detailed. Detailing includes the
identification which equipment, material and information are
required for a respective work task. Additionally, the required
personnel deployment is derived and an implementation plan
for the introduction of the production system is created.
System implementation: The operating resources are
procured and installed. The personnel is trained and test
operations are started. The production quantity is continuously
increased. Occurring errors and weak points are eliminated.
System operation: After the successful test operation, the
system operation is launched. The final documentation is
prepared and success is monitored.
Several development methodologies for production systems
were defined based on this general procedure. Within the
Collaborative Research Center CRC 336, a methodical support
was created which reduces the development time by an
integrated product development [12]. In the guideline VDI
4499 [13], a factory planning approach is defined, starting from
layout planning up to series production. Wiendahl et al. define
an approach for production development divided in general
phases like process planning, facilities planning, assembly and
commissioning, start-up and series production [14].
Due to the increasing complexity and networking of
production systems, some approaches focus specifically on the
development of cyber-physical production systems. These
consist of Cyber-Physical Systems, a term introduced in 2006
by Gill [15], which are highly networked technical objects
containing embedded systems, exchanging digital information,
and using other services, connected to the environment via
sensors, storing recorded data and evaluating them with the
help of services. The physical world can also be directly
influenced via actuators. They are connected via the Internet of
Things and the Internet of Services, which link identifiable
services and physical objects over the internet so that they
communicate with each other independently, thereby providing
enhanced functionality and generating additional customer
value [1]. CPPS are production systems with the characteristics
of a CPS in addition to representing a socio-technical system.
The goal of operating a production system is to produce the
right products at the right time in the defined quality at
reasonable costs. CPPS are able to collect process information
and evaluate it by using artificial intelligence [16].
One approach in CPPS development is proposed by
Berardinelli et al. [17], who define an model-driven
engineering tool chain for the development of CPPS. In a case
example, model-based engineering activities and languages are
defined within a V-Model without considering the integrated
interaction between product and production system.
2.3. Integrated product system development
Integrated product development methods trace back to the
original model proposed by Olsson [18]. The tasks of the four
 Iris Gräßler et al. / Procedia CIRP 100 (2021) 253–258 255
Author name / Procedia CIRP 00 (2019) 000–000 3

core teams (market, development/design, manufacturing and
project administration and management) of a development
process are synchronized and planned to start simultaneously
to reduce development time. Andreasen and Hein reduced the
number of teams by reordering the task [19], while Ehrlenspiel
focuses on team aspects and collaboration [20] and Vajna on
the integration of human centric design [21]. As a result of
synchronizing the development of the product and production
system, the time to market is reduced as well as inconsistencies
in both processes can be identified as early as possible by
continuous exchange of information. [21]
terms of quality criteria and the review protocol. Therefore, all
articles apart from domains 'Engineering', 'Manufacturing' have
been excluded. After reading the title and abstract of the papers,
unrelated papers were excluded. Furthermore, when reading
the relevant papers, some relevant complementary papers were
also selected from the references. The search strategy resulted
in 53 papers for further-analysis, shown in table 2.
Table 2. Search results.
Science Direct
Search terms

Total hits

Comple-
Selected

mentary
3. Procedure

The paper at hand presents a systematic literature review to Terms="integrated product development" AND 27 8 5
capture integrated development approaches of CPS and CPPS. (“Cyber physical systems” OR CPS) AND
The procedure is based on the method proposed by Briner and (approach OR methodology OR systematic)
Denyer [22]: Identify, Locate and Select, Critical Appraise, Terms="simultaneous engineering" AND 29 8 4
Analyze and Synthesize, Disseminate. By using this review (“cyber physical systems” OR CPS) AND
procedure, the distortions by declaring the search process and (approach OR methodology OR systematic)
defining specific inclusion/exclusion criteria are minimized. Terms="concurrent engineering" AND (“cyber 149 9 3
The individual steps of the review process are described in physical systems” OR CPS) AND (approach
detail below. OR methodology OR systematic)
Step 1 – Identify review question: The question must be Terms= ”production system development” 32 6 2
precise, answerable and meaningful. Hence, it is defined as AND "integrated development" ("cyber
physical production systems" OR CPPS) AND
follows: Which approaches address integrated development of
(approach OR methodology OR systematic)
product and production system, with a focus on cyber physical
Terms= ”production system development” 10 5 1
system and cyber physical production systems?
AND "simultaneous engineering" ("cyber
Step 2 – Locate and select relevant studies: A protocol physical production systems" OR CPPS) AND
based on the review question is developed. Science Direct was (approach OR methodology OR systematic)
primarily used to search for articles because of the high quality Terms= “production system development” 31 10 4
results in context of CPPS. Papers published from 2006 AND "concurrent engineering" ("cyber physical
(introduction of the term CPS by Gill [15]) to 2020 were production systems" OR CPPS) AND
analyzed. Based on the literature analysis the following search (approach OR methodology OR systematic)
terms were used: “integrated product development”, “simul- Total 278 37 16
taneous engineering”, “concurrent engineering”, “production
system development”, “cyber physical systems”, “CPS”, Step 4 – Analyze and synthesize the findings from the
“cyber-physical production systems”, “CPPS”, “approach”, Studies: All approaches related to the review question are
“methodology”, “systematic” (see table 1). collected, analyzed, and synthesized. The goal of the analysis
This resulted in a total of 278 papers on Science Direct. is the examination of existing procedures for the integrated
Table 1. Search strategies. development. The papers were finally shortlisted and analyzed.
Step 5 – Disseminate the review findings: One of the main
ScienceDirect purposes of systematic reviews is to make findings more
Search 1. Advanced Search accessible. This paper integrates the results of the review into
strategies 2. (integrated product development OR simultaneous the V-Model 2206:2020. Additional questions are defined for
engineering OR concurrent engineering) AND
the checkpoints. The following chapter shows the analysis and
3. (cyber physical systems OR CPS OR cyber physical
production systems) AND the assignment.
4. (approach OR methodology OR systematic)
5. Language: English 4. Control Questions for integrated development of CPS
6. Time span: 2006-2020 and CPPS
Refinement Including articles in ‘Engineering’ domains
Selection The selected papers are analyzed to identify requirements,
Excluding unrelated articles by reading the titles and the
abstracts in detail
guidelines and information for the integrated development of
CPS and CPPS. The findings are clustered and discussed within
Analyzing relevant articles (some relevant articles cited in
reference were also selected).
a remote collaboration tool. The information gained was
formulated into control questions as well as existing questions
of the VDI 2206:2020 guideline were adopted for the integrated
Step 3 – Critically appraise the studies: A crucial step in any development of CPS and CPPS. The resulting 86 control
systemic review is that the approaches are critically assessed in questions were subsequently assigned to the control points of
256 Iris Gräßler et al. / Procedia CIRP 100 (2021) 253–258
4 Author name / Procedia CIRP 00 (2019) 000–000
the VDI 2206:2020. The questions were clustered and
prioritized to reduce the number of questions per control point
to five to ten, to filter redundancies and to cover all task to be
completed at each checkpoint.
The first checkpoint (see table 3) includes the connection to
the strategic planning of the enterprise. On the one hand, the
development of the CPPS has to be in line with the project
budget and the company’s strategic. On the other hand, it is
necessary to define the operative conditions by defining goals
and assigning responsibilities.
Table 3: Additional control questions of checkpoint 1 [11, 23–28]
Checkpoint 1:
Business case
❑ Has the initial situation been analyzed and based on
valid, documented information?
❑ Has a business case check-up been carried out, taking
into account existing production systems of this type?
❑ Are the goals of the development of CPS and CPPS
clearly defined? Are all dimensions of the goals to be
achieved defined? (Organizational goals, technical
goals, cost goals, personnel goals)
❑ Are the activities/milestones of the product
development and production system development
planned? Should the development be synchronized (i.e.
simultaneously engineered)?
❑ Are the planning responsibilities defined (e.g.in-house
experts involved, project manager)
❑ Was a first theoretical design created to estimate the
scope, consequences and investment costs? Has a
process for requirements management and ECM been
implemented?
In Checkpoint 2 (see table 4), the requirements are collected
and defined. In addition, one needs to ensure whether the
product program and the resulting requirements on the
production system are in line with the overall objectives.
Table 4: Additional control questions of checkpoint 2 [1, 11, 23, 24, 26–30]
Checkpoint 2:
Specification
❑ Has a production program (product portfolio, type,
variants, ...) been defined based on the defined goals?
❑ Have all relevant requirements for the development of
CPS and CPPS been derived from the main feature list?
(Responsiveness, Adaptability, human system
collaboration, connection the Internet of Things and
Services)?
❑ Are the requirements clearly formulated and/or
measurable? Are the requirements complete, correct
and consistent? Is it defined how the requirements are
ensured in the later process?
❑ Are limits of the considered production system defined?
❑ Was the design specification formulated?
Starting from the specification, an overall solution structure of
the CPPS is developed in the Sub-Section “Architecture” (see
table 5). Different alternatives of the cross-disciplinary
development of the CPPS are derived and the best possible
solution is selected. In order to fulfil the specification, the
control questions check not only the implementation but also
the completeness of the alternative solutions developed.
Table 5: Additional control questions of checkpoint 3 [1, 11, 25–31]
Checkpoint 3:
Architecture
❑ Are the necessary models (e.g. function structure,
principle solutions, sub-system concepts) created and
principles (e.g. lean manufacturing, Design for X) for
the development of CPS and CPPS considered?
❑ Are all solution variants within the technical-economic
and employee-related solution space?
❑ Were make-or-buy decisions made?
❑ Are the preparations for the process sequences
including all parts, assembly, guidance system and
assembly processes prepared?
❑ Have production techniques been selected based on
quality (e.g. tolerances), quantity, material and cost?
❑ Are workstations and operations specified and detailed?
Is it specified which material, parts, tools, equipment,
testing and measuring devices must be provided?
❑ What degree of automation is aimed for? Has the degree
of automation been defined?
❑ Are relevant interfaces to global networking of the
system (IoT) and layers (e.g. configuration level,
connection level) known and described?
During the implementation, the workstations and sub-systems
are designed, constructed, and detailed (see table 6). In
addition, it is determined which machine technologies and
employee skills are needed to fulfil the production program.
Table 6: Additional control questions of checkpoint [1, 11, 26, 28, 30]
Checkpoint 4:
Implementation
❑ Is the virtual and real planning available and released by
the decision makers?
❑ Have all procurements been initiated?
❑ Can the specified degree of automation be achieved?
❑ Have layouts, dimensions, designs and details of
sensors, actuators, software and interfaces to the
Internet of Things and Services been implemented?
❑ Are the features of a CPPS considered (e.g. cyber
security, human system collaboration, simulation
models)?
❑ Is information available about handling, data transfers
and integrated services?
❑ Have all necessary employee qualifications been
determined?
Once all required technologies and capabilities have been
determined, the successful integration of all systems in the
production system is ensured (see table 7). Afterwards, the first
test run is performed.
 Iris Gräßler et al. / Procedia CIRP 100 (2021) 253–258
Author name / Procedia CIRP 00 (2019) 000–000
Fig. 2: Case example of the integrated development of CPS and CPPS based on the VDI 2206:2020 and their extended control questions
Table 7: Additional control questions of checkpoint 5 [1, 11, 23, 28]
Checkpoint 5:
Integration
❑ Are all sub-systems installed in accordance with the
rules, standards and legal requirements in terms of
workstations and manufacturing processes?
❑ Were specified tolerances and test sequences achieved?
Have all observed errors been eliminated?
❑ Have deviations from specifications and necessary
changes been communicated (Change Requests)?
❑ Do maintenance schedules/ maintenance plans/
preventive quality management plans exist?
❑ Has the test operation been carried out successfully?
Are technical and personnel start-up difficulties
overcome?
In the last phase, the CPPS is moved from test run to the
regular operation (see table 8). Additionally, all documentation
and supporting documents are compiled. Finally, the
production system is put into operation and meets the customer
expectations.
Table 8: Additional control questions of checkpoint 6 [1, 11, 23, 28]
Checkpoint 6:
Transition
❑ Are plans for control and maintenance agreed upon?
❑ Have options such as virtual support for commissioning
been considered?
❑ Are all relevant product development information
considered in product system development?
❑ Are continuous improvement process measures
successfully implemented?
❑ Has the target control been carried out?
❑ Are final documentations prepared and handed over?
❑ Has internal and external customer satisfaction been
ensured?
5. Case Example
In this case example, the application of the new control
questions is illustrated within the development process of a
remote control car as an exemplary CPS and a decentralized
CPPS. The considered CPPS is the Smart Automation Lab. The
integrated development is evaluated by a retrospective analysis
257
5
referencing existing documentation of the original
development steps. We assume all logical developments tasks
were originally executed until all control questions for each
checkpoint could be answered positively:
In the first step of the development, the current situation is
analyzed and strategic goals are defined. Balanced Scorecards
are used to define goals from different perspectives. A Gantt
diagram serves as a Milestone Plan and allows to schedule and
measure the objectives of the project. All relevant documents
of the current situation are complied, for example stakeholders
or abilities of current employees. On the basis of their abilities
a project team is established.
Based on the product program, required manufacturing
technologies are derived to define requirements. Due to the
customized manufacturing and the necessary assembly process,
requirements concerning the adaptability of workstations and
human system interaction are included. By means of the main
feature list, the completeness of the requirements is ensured. To
facilitate traceability, verification and validation, the
development of a system model modeled in SysML is assumed.
Based on the information available, offers for the required
systems are obtained, to gain a first cost estimation.
An architectural model of the CPS and CPPS is created. The
system is decomposed into logical sub-systems, realizing the
required function in different ways. Using the morphological
box, different variants of the structure are designed. The best
solutions for the product elements and productions techniques
are selected based on quality-, cost- and time-specific criteria.
The degree of automation is defined and measured using the
defined levels and stages of [32].
In the next step a layout plan is created. Based on the plan,
the procurement is delegated. Domain-specific models are
created to detail the sensors, actuators and software. Additional
to the original approach, each workstation should be matched
to the human-machine interactions. For this purpose,
simulation models, e.g. human models, can be used. Employee
profiles can be used to initiate further training.
When the workstations are delivered, successful installation
and integration of the systems is ensured. For this purpose, the
requirements are verified and requirement changes are tracked
within a net graphic. In addition to the project team, a
standardization expert is contracted to ensure the security and
to enable an initial test of the production system. Before the
test, employees are instructed on site. In addition, documents
on machine operation are standardized. During the test run, the
system behavior is observed, data is collected and employees
are asked about the initial experiences in interviews.
258 Iris Gräßler et al. / Procedia CIRP 100 (2021) 253–258
6 Author name / Procedia CIRP 00 (2019) 000–000
In the last step of the development, the CPS and CPPS is
handed over with a complete documentation. In a meeting with
the management board, satisfaction of the requirements is
ensured. Additionally, a continuous improvement process is
implemented by using a key performance indicator like OEE,
mean time to repair or first pass yield. The analysis of the
documents ensured the applicability of the checkpoints.
Retrospectively, additional models and methods were
identified to reduce development effort and increase the quality
of the integrated development.
Overall, it has been shown that the determined checkpoints
provide good support in the application. Due to the factual
logical structure, the current maturity of the development
process can be easily seen and communicated. A problem of
the procedure is the different unconnected models. Therefore,
no entire consistency is reached.
6. Conclusion
The paper at hand presents an extension of the existing
control questions of the VDI guideline 2206:2020 with focus
on the integrated development of CPS and CPPS. Based on a
three-step approach control questions are derived from relevant
literature, which was identified in a comprehensive literature
research, extended by standard literature. The derived
questions were assigned to the existing checkpoints of the VDI
2206:2020, clustered and prioritized. The checkpoints
represent implications of the checkpoints of the V-Model for
the integrated development of CPPS. The linkages and
dependencies between the existing control questions for CPS
and the derived questions for CPPS enable the integrated
development of CPS and CPPS, for example in form of
simultaneous engineering. The results for each of the six
checkpoints are five to nine control questions which support
the CPPS development team members and enables the effective
development of CPS and CPPS. These questions ensure
sufficient system maturity before advancing to next logical
group of tasks. Therefore, a methodical support for system
designers of CPPS for CPS and enable the project manager to
check the maturity of the whole, integrated development is
given. Through this methodical support, the emerging
requirements for the integrated development of CPS and CPPS
can be fulfilled. In future research, the combination of the
digital model with real-time information will enable the
creation of a digital twin.
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