System-level concept modelling and simulation : For design exploration and decision support in conceptual product development

Sammanfattning

Modern vehicles are becoming increasingly complex systems, combining mechanical components, electronics, control systems, sensors, and software. This complexity creates challenges in early product development, where important design decisions must be made despite limited information and uncertainty. Design problems are often identified late in the development process, when physical prototypes have already been built, making changes more costly and time-consuming. System-level simulation offers a way to model and analyse system behaviour at a higher level of abstraction, enabling earlier exploration of system interactions, design alternatives, and potential development risks. This thesis investigates how system-level simulation can support early-stage decision-making in vehicle development. The study focuses on the conceptual design phase and was conducted as an exploratory case study at Scania, a manufacturer of heavy-duty vehicles. The research combines insights from existing literature with 26 interviews involving engineers, managers, technology suppliers, and academic experts. The findings show that system-level simulation can support design exploration, improve understanding of system behaviour, and enable more informed decisions earlier in the development process. However, adopting this approach is not only a technical challenge. Barriers include fragmented tools, limited access to suitable models, insufficient modelling practices, and development processes that are not fully adapted to early-phase simulation. The thesis concludes that successful adoption requires both technological capabilities and organizational changes related to workflows, knowledge exchange, and process management. By combining insights from research and industry practice, the thesis provides recommendations for how automotive manufacturers can strengthen their simulation capabilities and move toward more simulation-driven product development.