MBSE-Based Workflow Development for Systems Integrator
Client: Industrial Automation Systems Integrator
Core Pain Point: The client faced frequent delays and unpredictable rework cycles in the execution of complex workflows, particularly during documentation handovers, human-machine data processing, and multi-role approval steps. These inefficiencies were traced back to poorly defined team interfaces and inconsistent task ownership, leading to elevated project costs and missed commissioning deadlines.
Objective: To design, simulate, and validate a high-efficiency operational workflow across human-system interfaces for a complex industrial automation project.
Approach: We applied a Model-Based Systems Engineering (MBSE) methodology enhanced with SimEvents-based workflow simulation and performance-driven KPIs.
1. Define the Problem & Deliverables
We started by working closely with project leads and technical teams to: Identify specific workflow pain points, including frequent clarification cycles and unclear role handoffs. Establish clear project deliverables linked to time, quality, and productivity KPIs. Set expectations for model scope and validation criteria. 🔹 Deliverable: Problem Statement, Operational Objectives, and Modeling Scope.
2. Develop Workflow Requirements
We conducted a structured requirement-gathering process to document: Key workflow KPIs (e.g., task durations, clarification count, resource utilization). Constraints, such as team composition, tool limitations, and skill levels. Industry-specific performance expectations (e.g., adherence to commissioning timelines). 🔹 Deliverable: SysML Requirements Diagram and Role Attribute Mapping.
3. Develop Workflow Architecture
We translated requirements into a workflow architecture by: Mapping key roles (technician, engineer, manager) to task responsibilities. Modeling activity diagrams and interaction points between teams and system tools. Embedding common edge cases such as miscommunication or feedback loops. 🔹 Deliverable: SysML Activity Diagrams, Team Interface Map, and Reusable Templates.
4. Build and Simulate Workflow Model
Using MATLAB SimEvents®, we created a simulation model including: Entities representing team members with attributes like experience, delay tolerance, and expected output quality. Queues and service blocks for process steps such as document reviews and data validation. Logic to measure delays, throughput, and resource load under varying conditions. 🔹 Deliverable: Parametric SimEvents Model aligned with MBSE structure.
5. Test and Analyze the Workflow Model
We ran scenario-based and Monte Carlo simulations to: Stress test the system under varying input conditions (e.g., sudden task overload, role unavailability). Tune key parameters such as handoff thresholds and review buffer sizes. Validate outcomes against original KPIs and adjust the architecture accordingly. 🔹 Deliverable: Simulation Statistics, Parameter Adjustments, and KPI Compliance Report.
6. Validate and Deploy Optimized Workflow
Final validation included: Reviewing simulation insights with stakeholders. Delivering a finalized MBSE template for ongoing use in similar projects. Providing recommendations for process changes or system configuration updates. 🔹 Deliverable: Final Workflow Package including Simulation Files, Recommendations, and Team-Specific Guidelines.