Date of Award


Publication Type

Doctoral Thesis

Degree Name



Industrial and Manufacturing Systems Engineering


Applied sciences, System of systems, Design for manufacturing, Design for assembly


ElMaraghy, Waguih




The aim of this research is to study emerging ramp up scenarios in the context of complex sociotechnical dynamic systems. These represent industrial and manufacturing companies that are facing fierce competition due to globalization and free trade, and the race to be in the market first with new products. Furthermore, for every manufacturer to launch their newly designed products in market and introduce the latest functionality attributes, or improve quality of their products, effective and fast ramp up is necessary for capturing a good market share. This makes the production ramp up a back bone in modern manufacturing; as its effective management enables faster ramp-up every time a change is brought in the quality, quantity features and fabrication at design, system and process level while integrating systems logical and physical enablers. In this context, models of ramp up scenario have been explored by setting up nonlinear system dynamic models in order to understand complex trends and behaviours for large and complex systems. Apart from that, novelty of these introduced system dynamic models is the set-up of an analogy to understand what impact they can produce when the respective parameters are perturbed and how this will affect the whole system and related sub-systems when they together form a system of systems (SOS). Prior research has demonstrated that variety, due to mass customization and personalization, introduces complexity in the design as well as in manufacturing process due to production mix. Complexity is modelled and implemented, not only at the system and sub system levels but also at machine level and product level, by improving design for assembly (DFA) and design for manufacturing (DFM). In the end, sociotechnical aspects and risk assessment involving "triple bottom line" impact factor analysis have been explored with respect to new product design by studying utility function and trigonometry. Finally, a comprehensive model is developed and analyzed with human behavior core attributes by applying Porter's theory of motivation and system dynamic. This model highlights major impacts of motivation theory, by providing intrinsic and extrinsic rewards impact on labor which enables an understanding of behavior pattern of labour in relation to work assigned. Lastly, but not the least, this dissertation has contributed and demonstrated the potential usefulness of modeling complex industrial sociotechnical systems by using system dynamic approach for ramp-up.