Airbus shows how manufacturers can benefit from product line engineering (PLE)

Modern products such as cars, household appliances, and consumer electronics are becoming increasingly complex. One of the main drivers for this development is the introduction of sophisticated software. As a result, manufacturers have to rethink and adapt their development processes in order to remain competitive. A look behind the scenes at Airbus shows how manufacturers can benefit from model-based product line engineering (PLE) and a sophisticated variant management solution.

Intelligent software is becoming a key component for a wide range of products, including devices and machines that used to work without any software at all. As a result, the products are getting much more complex, and the number of variants is increasing significantly. This is especially true where companies offer different models and versions of a product, and where new features are being added at a later stage through software updates.

Companies facing these or similar challenges can learn a lot from the aircraft industry. After all, there is hardly a product that is as complex as an airplane. The latest development strategy at Airbus, where the entire product portfolio is already being developed digitally, should therefore be of interest to manufacturers from all industries.

While the focus at Airbus used to be exclusively on the actual aircraft itself, the product is now viewed holistically, including the entire lifecycle: from creating prototypes, to classic development and the supply chain, to after-sales services such as maintenance and repairs. Everything is developed and considered at the same time, as every little aspect can have an impact on other parts of the product. Thinking in systems rather than hierarchically is a huge success at Airbus.

With the help of co-development and co-architecture, Airbus is tackling strategic corporate goals such as a zero-emissions model for civil aviation. The faster Airbus will reach this goal, the fuller the order books are likely to be, as airlines have to switch to more environmentally friendly solutions in order to meet the demands of customers, industry standards, and government guidelines. However, Airbus isn’t only trying to become more sustainable by creating innovative new products such as low-emission aircraft, but also by optimizing their product development. The company is already becoming more sustainable by amending its development processes, which include comprehensive digitization and methods such as modern PLE.

PLE and model-based systems engineering
Airbus uses two methods to modernize the development processes: PLE and model-based systems engineering (MBSE). Combining these methods has two major advantages. On the one hand, Airbus can now show customers new features of a product even before a prototype has been created. On the other hand, Airbus doesn’t want to focus solely on all the required components, but also on the actual needs of their customers, and how they can benefit from new solutions. This customer-focused approach is made possible by the consistent use of model-based PLE (MB-PLE). If a customer wants a product to be individualized, Airbus can now create a digital twin, and show the customer in detail how complex the required changes are – and whether there is a simpler, cheaper way to achieve the same goal.

For the development of the product line cabin systems, Airbus uses a German software solution that’s been designed for the holistic management of thousands of product variants. This way, Airbus can deal with the specific wishes and demands of each airline much faster – and more reliably. The software solution pure::variants has been developed by the Magdeburg-based company pure-systems and is already being used in a wide range of industries and companies, including well-known car manufacturers, but also medium-sized companies that develop software-based products with many variants.

Which variants are possible – or mutually exclusive
Thinking and developing in product lines enables companies to operate much more efficiently, as individual parts and assets that are used in several models and variants can be reused easily. If an airline wants additional rows of seats, more legroom or more storage space for hand luggage, Airbus can easily change and illustrate the cabin system thanks to MB-PLE. And with the help of pure::variants, Airbus can immediately tell which variants are possible - and which features and combinations are mutually exclusive. In addition, the solution enables Airbus to identify which parts can be reused, which ultimately also results in large savings, as the number of parts that need to be developed and created can be reduced significantly.

Another reason why companies such as Airbus use pure::variants is the availability of connectors for a wide range of development tools, for example for requirement management, source code management, simulation or test cases. This way, the variance can be managed in one central system. Thanks to this holistic variant management approach, all information from all relevant departments is being considered at all times – regardless of whether a department or member of staff uses a text- or model-based tool. This procedure allows manufacturers to consider all aspects from the start when developing new products and variants.

Benefits from reusing hardware, software elements
After the successful digitization in areas such as cabin systems, Airbus now wants to extend the use of MB-PLE to other areas within the group in which holistic variant management would also lead to more efficiency and sustainability. In the ongoing battle with Boeing and other competitors, this could prove to be decisive.

While many manufacturers and suppliers in the automotive industry are already developing their products in similar ways to Airbus, other companies can still learn a lot from the European aircraft manufacturer – especially when developing product lines. A comprehensive variant management that enables the efficient reuse of hardware and software elements is crucial for the long-term success of any manufacturer.

About the author: Tillmann Braun is a freelance journalist, based in Haiterbach, Germany. His articles and stories cover B2B and B2C IT solutions and related topics, such as IoT, PLE, home networks and alternative energies. He can be reached at braun@tbraun.com.