Engineering complex systems and New Product Development (NPD) are major challenges for contemporary engineering design and must be studied at three levels of: Products, Processes and Organizations (PPO). The science of complexity indicates that complex systems share a common characteristic: they are robust yet fragile. Complex and large scale systems are robust in the face of many uncertainties and variations; however, they can collapse, when facing certain conditions. This is so since complex systems embody many subtle, intricate and nonlinear interactions. If formal modelling exercises with available computational approaches are not able to assist designers to arrive at accurate predictions, then how can we immunize our large scale and complex systems against sudden catastrophic collapse? This thesis is an investigation into complex product design. We tackle the issue first by introducing a template and/or design methodology for complex product design. This template is an integrated product design scheme which embodies and combines elements of both design theory and organization theory; in particular distributed (spatial and temporal) problem solving and adaptive team formation are brought together. This design methodology harnesses emergence and innovation through the incorporation of massive amount of numerical simulations which determines the problem structure as well as the solution space characteristics. Within the context of this design methodology three design methods based on measures of complexity are presented. Complexity measures generally reflect holistic structural characteristics of systems. At the levels of PPO, correspondingly, the Immunity Index (global modal robustness) as an objective function for solutions, the real complexity of decompositions, and the cognitive complexity of a design system are introduced These three measures are helpful in immunizing the complex PPO from chaos and catastrophic failure. In the end, a conceptual decision support system (DSS) for complex NPD based on the presented design template and the complexity measures is introduced. This support system (IMMUNE) is represented by a Multi Agent Blackboard System, and has the dual characteristic of the distributed problem solving environments and yet reflecting the centralized viewpoint to process monitoring. In other words IMMUNE advocates autonomous problem solving (design) agents that is the necessary attribute of innovative design organizations and/or innovation networks; and at the same time it promotes coherence in the design system that is usually seen in centralized systems.

Engineering complex systems and New Product Development (NPD) are major challenges for contemporary engineering design and must be studied at three levels of: Products, Processes and Organizations (PPO). The science of complexity indicates that complex systems share a common characteristic: they are robust yet fragile. Complex and large scale systems are robust in the face of many uncertainties and variations; however, they can collapse, when facing certain conditions. This is so since complex systems embody many subtle, intricate and nonlinear interactions. If formal modelling exercises with available computational approaches are not able to assist designers to arrive at accurate predictions, then how can we immunize our large scale and complex systems against sudden catastrophic collapse? This thesis is an investigation into complex product design. We tackle the issue first by introducing a template and/or design methodology for complex product design. This template is an integrated product design scheme which embodies and combines elements of both design theory and organization theory; in particular distributed (spatial and temporal) problem solving and adaptive team formation are brought together. This design methodology harnesses emergence and innovation through the incorporation of massive amount of numerical simulations which determines the problem structure as well as the solution space characteristics. Within the context of this design methodology three design methods based on measures of complexity are presented. Complexity measures generally reflect holistic structural characteristics of systems. At the levels of PPO, correspondingly, the Immunity Index (global modal robustness) as an objective function for solutions, the real complexity of decompositions, and the cognitive complexity of a design system are introduced These three measures are helpful in immunizing the complex PPO from chaos and catastrophic failure. In the end, a conceptual decision support system (DSS) for complex NPD based on the presented design template and the complexity measures is introduced. This support system (IMMUNE) is represented by a Multi Agent Blackboard System, and has the dual characteristic of the distributed problem solving environments and yet reflecting the centralized viewpoint to process monitoring. In other words IMMUNE advocates autonomous problem solving (design) agents that is the necessary attribute of innovative design organizations and/or innovation networks; and at the same time it promotes coherence in the design system that is usually seen in centralized systems.