The project, carried out by the Karlsruhe Institute of Technology (KIT) together with the Friedrich‑Alexander‑University Erlangen‑Nürnberg (FAU) and their respective research units – the Institute of Product Engineering (IPEK) and the KTmfk – Engineering Design – develops a structured approach for early robustness evaluation of product concepts. The core contribution is an adaptive modelling method that integrates the Embodiment Function Relation and Tolerance (EFRT) model, a qualitative tool that represents system properties without requiring detailed quantitative data. By recognising that the amount of specific design knowledge (SDK) available at the start of a project can vary widely, the method tailors its modelling activities to the actual level of SDK that can be derived from the design situation.

The workflow consists of five stages and gates, each of which explicitly incorporates the derivable SDK. In the initial stage, the concept is sketched and the available information is assessed. Depending on whether the SDK is high – for example, when concrete references or detailed data exist – or low – such as when only abstract sketches are available – the subsequent stages adjust the depth of modelling. In the sketch stage, ideation techniques like TRIZ, the 6‑3‑5 method or brainstorming can be integrated to generate alternatives. The next stage, exploratory modelling, uses the EFRT framework to capture functional relationships and tolerances qualitatively. If sufficient SDK is present, a more deductive modelling phase follows, where analytical methods such as SPALTEN can be applied to refine the model. The final stages involve validation against robustness criteria and documentation of the concept’s tolerance envelope. The method was demonstrated in two contrasting case studies, one with a high level of derivable SDK and one with a low level, showing that the adaptive workflow can accommodate both scenarios without compromising the rigor of the robustness assessment. Although the report does not report specific numerical performance figures, it demonstrates that the EFRT‑based approach can be applied early in the design cycle, potentially reducing costly iterations later on.

The collaboration between KIT and FAU brings together expertise in product engineering, systems design and quality management. IPEK provides the theoretical foundation for product engineering, while KTmfk contributes practical experience in engineering design and early concept development. The project’s outputs are disseminated under a Creative Commons Attribution‑ShareAlike 4.0 International licence, ensuring that the methodology can be freely adopted and adapted by other research groups and industry partners. While the report does not specify a particular funding source or a fixed project duration, the joint effort reflects a broader commitment within the German research community to advance early robust design practices. Future work will focus on empirical validation in industrial settings and on extending the EFRT model to incorporate additional design principles and simulation tools, thereby strengthening the link between early concept robustness and final product performance.