Optimizing Hardware Design: Reducing Iterations with DSM

• Hardware Development
• Product Design
• Optimization

Hardware development is rarely straightforward. Between complex interdependencies, long product development cycles, certification requirements, and more, even minor design changes can trigger significant ripple effects. Managing these intricacies efficiently is critical to avoiding costly delays and unnecessary iterations. This article provides a brief introduction to how systems architecture tools like the Design Structure Matrix (DSM) can be used to manage these complexities, keeping the product on track and avoiding the purgatory of change propagation.

What is DSM?

Design Structure Matrix (DSM), (sometimes called Dependency Structure Modeling), is a matrix-based tool used for managing complexity by mapping out system elements and their interactions. It provides a compact, structured way to capture relationships between components and help teams break down and visualize dependencies, making it easier to design, refine, and optimize complex architectures—whether for products, organizations, or processes.

For hardware development, it could be used to optimize development sequences, balance user and business needs, make informed decisions when handling change requests, reduce unnecessary iterations, and streamline the entire hardware development process.

Applications of DSM in Hardware Development

1. Managing Change Requests Efficiently
   
   Changes are inevitable in any project, but in hardware, they can be especially disruptive. DSM helps visualize how different components interact, ensuring that modifications are sequenced logically,  minimizing the risk of unintended consequences, reducing redundant work, and avoiding unnecessary Iterations
2. Mapping Requirements to Dependencies
   
   Unlike software, hardware development follows a more rigid, waterfall-like approach due to manufacturing constraints, certification requirements, and longer product lifecycles. DSM could help teams map requirements to dependencies early to ensure they are addressed appropriately, reducing costly redesigns and development delays.
3. Prioritizing User and Business Needs
   
   Not all changes are created equal. DSM can be useful in balancing technical feasibility with business priorities, by clarifying the impact of user requests and business objectives across the system(Product), ensuring that critical improvements take precedence over less essential modifications.
   By structuring dependencies, teams can identify which features or optimizations will have the highest impact on user experience and product success, guiding decision-making.
4. Improving Cross-Functional Collaboration
   
   Hardware development requires tight coordination across mechanical, electrical, firmware, and manufacturing teams. DSM provides a common framework for these disciplines to communicate and plan effectively.

Using DSM in Hardware Design

There are tons of resources and open-source DSM tools on https://dsmweb.org/ so I won’t get into the details of constructing or using a DSM, but below is a quick breakdown of the steps involved with an example. 

Step 1: Breaking Down the System

List all key components—PCB, sensors, power system, enclosure, firmware, features, etc., under consideration. 

Step 2: Mapping Dependencies

Create an N × N matrix where both the rows and columns represent the system components. This matrix will capture the relationships between these components, populate it with dependency relationships—marking where one component influences or depends on another. This helps visualize interconnections, pinpoint potential bottlenecks, and optimize workflows within the system.

Step 3: Reordering for Efficiency

Rearrange the matrix to sequence tasks in a way that minimizes feedback loops and unnecessary rework. Components with the highest-impact dependencies should be addressed first, preventing cascading issues. You can also create clusters to identify components that can be addressed together. This step ensures a smooth progression through the development lifecycle.

Application Example

Let’s look at an Example: 

Consider a team developing a next-generation industrial controller for Off-Highway Vehicles. After launching the first version, the list below represents changes and new features that they need to implement;

1. Switching to a new microcontroller to improve processing speed
2. Upgrading the wireless module to support a broader range of frequencies
3. Redesigning the power system to accommodate a new battery standard
4. Modifying the enclosure for better heat dissipation and durability
5. Adjusting the firmware to support enhanced real-time processing

Step 1: Mapping Dependencies

The team constructs a DSM to analyze how these requests interact:

Step 2: Analyzing the DSM

This Mapping shows that:

• The Microcontroller Upgrade impacts the most components (Power, Wireless, and Firmware), making it the highest priority.
• The Power System Redesign must be implemented before finalizing the Wireless Module and Firmware Adjustments.
• The Wireless Module Upgrade affects both firmware and power systems, meaning it should come after both of those are stable.
• The Enclosure Modification is largely independent and can be scheduled separately.

Step 3: Optimizing Execution Order

Based on the DSM, the team prioritizes changes in the following sequence:

1. Upgrade the Microcontroller – Establishes a stable platform for firmware and power modifications.
2. Redesign the Power System – Ensures compatibility with the new microcontroller and battery standard.
3. Upgrade the Wireless Module – Requires stable power and microcontroller configurations.
4. Adjust Firmware – Final firmware development can be optimized once hardware components are locked down.
5. Modify the Enclosure – Since it has minimal electrical dependencies, it can proceed independently.

Conclusion

Design Structure Matrix is more than just a visualization tool—it’s a practical framework for managing complexity in hardware development. Whether you’re handling design changes, streamlining product iterations, or navigating regulatory requirements, DSM provides a structured way to minimize risk, reduce delays, and optimize workflows.

By integrating DSM into the hardware development process, engineering teams can work smarter, make informed decisions, and ultimately bring high-quality products to market faster.

More information on the applications of DSM along with opensource and commercial DSM tools can be found here: https://dsmweb.org/

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