The Limits of Document Based Engineering

If you remember the era of procedural programming, you likely recall the resistance that came with the shift to object-oriented methods. Paradigm shifts in engineering rarely happen because of enthusiasm for new methods—they happen out of necessity. The complexity of modern systems demands it. Today, document-based engineering is facing its limits in cyberphysical product development. And this is driving not just one, but two fundamental shifts in engineering thinking.

From Components to Functions: The First Paradigm Shift

For decades, mechanical design followed a component-based approach. Engineers would specify parts, document them, and gradually assemble them into a finished product. But in cyberphysical systems—where mechanical, electrical, and software elements are tightly interwoven—this approach is no longer effective. More and more development teams are shifting toward function-oriented design: instead of focusing on individual parts, they emphasize functions, interactions, and system behavior.

This change affects not only how engineers think, but also the tools they use. Functions can’t be cleanly represented in traditional document-based engineering workflows. What’s needed is a holistic, systems-level understanding that unites all engineering disciplines—and that leads us to the second major shift.

Document-Based Engineering Is Reaching Its Limits

The second major change affects the foundation of collaboration: the decline of document-based methods. For a long time, requirements documents, specifications, and checklists were the core tools of product development. But in today’s environment—with high variant complexity, parallel disciplines, and iterative cycles—document-based engineering is declining.

Documents often follow inconsistent structures, heavily influenced by the individual author. It’s difficult to distinguish what’s important from what’s not, and requirements must be manually translated into specifications—a process prone to error and ambiguity. Tracking changes across multiple versions is cumbersome, and comparing multiple sets of requirements is nearly impossible using conventional documents.

Taking their place is a new approach: Model-Based Systems Engineering (MBSE). With system models, engineers can visualize complexity, make dependencies transparent, and trace changes consistently. This isn’t just digitizing paper documents—it’s a fundamentally new way to design systems: cross-disciplinary, iterative, and scalable.

From Theory to Practice: MBSE Becomes Mainstream

Until recently, MBSE was mostly limited to aerospace—an industry known for its complex systems and strict safety demands. In other industries, practical paths to integrate MBSE into everyday processes were lacking. That’s now changing—and from two directions.

First, MBSE experts are beginning to understand the unique complexity challenges faced in mechanical engineering, automotive, and electronics. It’s not just about large systems—it’s about product families, configuration variants, and frequent changes, which traditional MBSE models often ignored.

Second, tool providers are evolving. It’s no longer enough to manage data. Tools must now help engineers actively shape development—in a model-based, interdisciplinary, and traceable way.

MBSE at Zuken: From Documents to Digital Models

Zuken is moving purposefully in this direction. The acquisition of Vitech and the integration of its MBSE tool GENESYS into Zuken’s portfolio marked a key milestone. Today, system models created in GENESYS can be seamlessly linked with the electrical and electronic design data in E3.series or CR-8000. At the same time, consistent data management remains intact across disciplines.

This integration lays the foundation for future-ready product development: system architecture, functional behavior, electrical design, and manufacturing data—all within a unified, coherent model rather than scattered documentation.

Conclusion: Sticking to Document-Based Engineering Is a Risk

The complexity of mechatronic systems can no longer be managed using yesterday’s tools. Document-based development today risks inconsistency, slow iterations, and cumbersome change management. Model-based approaches like MBSE are no longer a theoretical vision—they’re essential for mastering modern product complexity.

With tightly integrated system modeling, ECAD, and data management, Zuken provides a practical path into this new engineering era—for machine builders and automotive suppliers alike.

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