Downloads: A PDF of this resource will be available soon.
Who is this article for?: Thisarticle should be read by educators at all levels in higher education who are seekingto provide students with an overall perspective on complex systems in engineering.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking and Critical Thinking INCOSE competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems).
Engineering systems today are increasingly complex, interconnected, and adaptive. To understand and manage them effectively, engineers must move beyond reductionist thinking where systems are broken into isolated parts and adopt systems thinking, which views systems as wholes made up of interacting components.
At the heart of this perspective lies emergence, a defining characteristic of complex systems. Emergence refers to properties or behaviours that arise from interactions among components but cannot be predicted or understood by examining those components in isolation. Appreciating emergence helps engineers anticipate how individual design decisions can produce system-level outcomes, sometimes beneficial, sometimes negative and unintended.
This article introduces the concept of emergence as one key characteristic of complex systems, situates it within systems thinking, and provides practical guidance for recognising and managing emergent behaviours in engineering practice.
1. What is a system?:
A system can be defined as “a set of interconnected elements organised to achieve a purpose” (Meadows, 2008). Systems possess structure (components), relationships (interactions), and purpose (function). Engineering systems such as aircraft, power grids, transport networks, or data infrastructures are composed of numerous subsystems that depend on each other.
Crucially, systems thinking emphasises interdependence and feedback. The behaviour of the whole cannot be fully explained by the behaviour of the parts alone. Properties such as resilience, adaptability, and emergence result from interactions within the system’s structure and environment. Recognising these relationships is essential to understanding how system-level behaviours arise.
Emergence describes the appearance of new patterns, properties, or behaviours at the system level that are not present in individual components. These properties are often irreducible: they cannot be explained solely by analysing each part separately (Holland, 2014).
Researchers distinguish between:
Weak emergence – behaviours that are theoretically predictable if all component interactions were known but are practically impossible to compute due to complexity (e.g. traffic flow patterns).
Strong emergence – properties that are fundamentally novel and irreducible to component-level descriptions (e.g., consciousness in biological systems).
In engineering, most emergent behaviours are weakly emergent: complex yet explainable with sufficient data and computational tools such as agent-based modelling or system dynamics.
A key caveat is that emergence depends on perspective and system boundaries. What seems emergent at one scale (e.g., the stability of a power grid) might appear straightforward when viewed at another. Therefore, engineers must define boundaries and assumptions clearly when analysing emergence.
3. Why emergence matters in engineering:
Emergence shapes how engineering systems behave, evolve, and sometimes fail. It can produce both desired outcomes (like adaptability or resilience) and undesired ones (like instability or cascading failure).
Understanding emergence enables engineers to:
anticipate how local interactions scale up to global system behaviour;
design feedback loops and architectures that promote stability; and
identify potential points for intervention when emergent behaviour becomes undesirable.
For instance, in cyber-physical systems, emergent coordination can enhance efficiency, but it may also create unpredictable vulnerabilities if feedback loops reinforce errors. Engineers therefore must not only observe emergence but learn how to influence it through design and governance.
4. Recognising and managing emergent behaviour:
Recognising emergence
Engineers can identify emergence by looking for:
System-level patterns that do not trace directly to any single component (e.g. global traffic flow or collective oscillations in a power grid).
Unexpected behaviours, such as new failure modes or self-organising phenomena.
Scale-dependent properties, where behaviour changes qualitatively as the system grows or interacts with its environment.
Adaptive or learning responses, where the system adjusts without explicit central control.
Intervening in emergent systems
Not all emergence is beneficial. Engineers often need to mitigate unwanted emergent behaviours such as instability or inefficiency while reinforcing desirable ones. Effective approaches include:
Redesigning interactions rather than individual components, focusing on how feedback and connectivity shape outcomes.
Introducing constraints or buffers to dampen runaway feedback loops.
Enhancing diversity and modularity so subsystems can adapt locally without propagating failures globally.
Monitoring system states continuously, using sensors, data analytics, or digital twins to detect emergent behaviour early.
Managing emergence requires humility: complex systems cannot be fully controlled, only influenced. The goal is to guide system dynamics toward safe and productive outcomes.
5. Illustrative examples of emergence in engineering systems:
Network systems
The Internet exemplifies emergence: billions of devices follow simple communication protocols, yet collectively create a resilient, adaptive global network. No single node dictates its performance; instead, routing efficiency and viral content propagation arise from local interactions among routers and users.
Transportation systems
Urban traffic patterns such as congestion waves, spontaneous lane formation, and adaptive rerouting emerge from individual driver behaviour and infrastructural design. Traffic engineers use simulation models to study how simple decision rules generate complex city-wide flows.
Energy systems
Electrical grids maintain frequency and voltage stability through distributed interactions among generators, loads, and controllers. Emergent synchronisation enables reliability, but loss of coordination can cause cascading blackouts showing both beneficial and harmful emergence.
Manufacturing systems
In smart factories, machines and sensors collaborate autonomously, producing system-wide optimisation in scheduling and quality control. Adaptive algorithms and feedback loops create emergent flexibility beyond what central planning alone could achieve.
6. Practical guidance for engineers and educators:
For engineers, the key is to design with emergence in mind:
focus on local rules that encourage desirable global behaviour;
incorporate feedback and sensing to detect changes early; and
use modular, diverse architectures to enhance resilience.
For educators, teaching emergence provides an opportunity to bridge theory and practice. Software such as NetLogo and Insight Maker allows students to visualise emergent behaviour through agent-based and system-dynamics models. Linking engineering examples to ecological, social, or digital systems helps learners appreciate the universality of emergence.
Conclusion:
Emergence is not an anomaly to be avoided but a natural attribute of complex systems. It challenges traditional engineering by revealing that system behaviour often arises from relationships, not components.
Understanding emergence equips engineers to recognise interdependencies, design adaptive solutions, and work with complexity rather than against it. By embracing systems thinking, engineers can create technologies that are not only functional but resilient, sustainable, and aligned with real-world dynamics.
References:
Holland, J.H. (2014). Complexity: A Very Short Introduction. Oxford: Oxford University Press.
Johnson, S. (2001). Emergence: The Connected Lives of Ants, Brains, Cities, and Software. New York: Scribner.
Mitchell, M. (2009). Complexity: A Guided Tour. Oxford: Oxford University Press.
Bar-Yam, Y. (2003). Dynamics of Complex Systems. Cambridge, MA: Perseus Publishing.
Helbing, D. (2013). Globally networked risks and how to respond. Nature, 497(7447), 51-59.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Relevant disciplines:Energy engineering; Chemical engineering; Process systems engineering; Mechanical engineering; Industrial engineering.
Keywords: Available soon.
Licensing:This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License. It is based upon the author’s 2025 article “A Simulation Tool for Pinch Analysis and Heat Exchanger/Heat Pump Integration in Industrial Processes: Development and Application in Challenge-based Learning”. Education for Chemical Engineers 52, 141–150.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, Systems Modelling and Analysis and Critical Thinking INCOSE competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems). In addition, this resource addresses the themes of Science, mathematics and engineering principles; Problem analysis; and Design.
Educational level: Intermediate.
Educational aim:To equip learners with the ability to model, analyse, and optimise pathways for industrial decarbonisation through a complex-systems lens – integrating technical, economic, and policy dimensions – while linking factory-level design decisions to wider value-chain dynamics, multi-stakeholder trade-offs, and long-term sustainability impacts.
Learning and teaching notes:
This teaching activity explores heat integration for the decarbonisation of industrial processes through the lens of complex systems thinking, combining simulation, systems-level modelling, and reflective scenario analysis. It is especially useful in modules related to energy systems, process systems, or sustainability.
Learners analyse a manufacturing site’s energy system using a custom-built simulation tool to explore the energy, cost and carbon-emission trade-offs of different heat-integration strategies. They also reflect on system feedback, stakeholder interests and real-world resilience using causal loop diagrams and role-played decision frameworks.
This activity frames industrial heat integration as a complex adaptive system, with interdependent subsystems such as process material streams, utilities, technology investments and deployments, capital costs, emissions, and operating constraints.
Learners run the simulation tool to generate outputs to explore different systems integration strategies: pinch-based heat recovery by heat exchangers, with and without heat pump-based waste heat upgrade. Screenshots of the tool graphical user interface are attached as separate files:
The learning is delivered in part, through active engagement with the simulation tool. Learners interpret the composite and grand composite curves and process tables, to explore how system-level outcomes change across various scenarios. Learners explore, using their generated simulation outputs, how subsystems (e.g. hot and cold process streams, utilities) interact nonlinearly and with feedback effects (e.g., heat recovery impacts), shaping global system behaviour and revealing leverage points and emergent effects in economics, emissions and feasibility.
Using these outputs as a baseline, and exploring other systems modelling options, learners evaluate trade-offs between heat recovery, capital expenditure (CAPEX), operating costs (OPEX), and carbon emissions, helping them develop systems-level thinking under constraints.
The activity embeds scenario analysis, including causal loop diagrams, what-if disruption modelling, and stakeholder role-play, using multi-criteria decision analysis (MCDA) to develop strategic analysis and systems mapping skills. Interdisciplinary reasoning is encouraged across thermodynamics, economics, optimisation, engineering ethics, and climate policy, culminating in reflective thinking on system boundary definitions, trade-offs, sustainability transitions and resilience in industrial systems.
Learners have the opportunity to:
Analyse non-linear interactions in thermodynamic systems.
Reconcile conflicting demands (e.g. energy savings vs costs vs emissions vs technical feasibility) using data generated from real system simulation.
Model and interpret feedback-driven process systems using pinch analysis, heat recovery via heat exchangers, and heat upgrade via heat pump integration.
Explore emergent behaviour, trade-offs, and interdisciplinary constraints.
Navigate system uncertainties by simulation data analysis and scenario thinking.
Understand the principles of heat integration using pinch analysis, heat exchanger networks, and heat pump systems, framed within complex industrial systems with interdependent subsystems.
Evaluate decarbonisation strategies and their performances in terms of energy savings, CAPEX/OPEX, carbon reduction, and operational risks, highlighting system-level trade-offs and nonlinear effects
Develop data-driven decision-making, navigating assumptions, parameter sensitivity, and model limitations, reflecting uncertainty and systems adaptation.
Explore ethical, sustainability, and resilience dimensions of engineering design, recognising how small changes or policy shifts may act on leverage points and produce emergent behaviours.
Analyse stakeholder dynamics, policy impacts, and uncertainty as part of the broader system environment influencing energy transition pathways.
Construct and interpret causal loop diagrams (CLDs), explore what-if scenarios, and apply multi-criteria decision analysis (MCDA), building competencies in feedback loops, system boundaries, and systems mapping.
Teachers have the opportunity to:
Embed systems thinking and complex systems pedagogy into energy and process engineering, using real-world simulations and data-rich problem-solving.
Introduce modelling and scenario-based reasoning, helping students understand how interactions between process units, energy streams, and external factors affect industrial decarbonisation.
Facilitate exploration of design trade-offs, encouraging learners to consider technical feasibility, economic sustainability, and environmental constraints within dynamic system contexts.
Support students in identifying leverage points, feedback loops, and emergent behaviours, using tools like CLDs, composite curves, and stakeholder role play.
Assess complex problem-solving capacity, including students’ ability to model, critique and adapt industrial systems under conflicting constraints and uncertain futures.
Proprietary Simulator for Pinch Analysis & Heat Integration. Freely available for educational use and can be accessed online through a secure link provided by the author on request (james.atuonwu@nmite.ac.uk or james.atuonwu@gmail.com). No installation or special setup is required; users can access it directly in a web browser.
About the simulation tool (access and alternatives):
This activity uses a Streamlit-based simulation tool, supported with process data (Appendix A, Table 1, or an educator’s equivalent). The tool is freely available for educational use and can be accessed online through a secure link provided by the author on request (james.atuonwu@nmite.ac.uk or james.atuonwu@gmail.com). No installation or special setup is required; users can access it directly in a web browser.The activity can also be replicated using open-source or online pinch analysis tools such as OpenPinch, PyPinchPinCH, TLK-Energy Pinch Analysis Online. SankeyMATIC can be used for visualising energy balances and Sankey diagrams.
Pinch Analysis, a systematic method for identifying heat recovery opportunities by analysing process energy flows, forms the backbone of the simulation. A brief explainer and further reading are provided in the resources section. Learners are assumed to have prior or guided exposure to its core principles. A key tunable parameter in Pinch Analysis, ΔTmin, represents the minimum temperature difference allowed between hot and cold process streams. It determines the required heat exchanger area, associated capital cost, controllability, and overall system performance. The teaching activity helps students explore these relationships dynamically through guided variation of ΔTmin in simulation, reflection, and trade-off analysis, as outlined below.
Introducing and prioritising ΔTmin trade-offs:
ΔTmin is introduced early in the activity as a critical decision variable that balances heat recovery potential against capital cost, controllability, and safety. Students are guided to vary ΔTmin within the simulation tool to observe how small parameter shifts affect utility demands, exchanger area, and overall system efficiency. This provides immediate visual feedback through the composite and grand composite curves, helping them connect technical choices to system performance.
Educators facilitate short debriefs using the discussion prompts in Part 1 and simulation-based sensitivity analysis in Part 2. Students compare low and high ΔTmin scenarios, reasoning about implications for process economics, operability, and energy resilience.
This experiential sequence allows learners to prioritise competing factors (technical, economic, and operational), while recognising that small changes can create non-linear, system-wide effects. It reinforces complex systems principles such as feedback loops and leverage points that govern industrial energy behaviour.
Data for decisions:
The simulator’s sidebar includes some default values for energy prices (e.g. gas and electricity tariffs) and emission factors (e.g. grid carbon intensity), which users can edit to reflect their own local or regional conditions. For those replicating the activity with other software tools, equivalent calculations of total energy costs, carbon emissions and all savings due to heat recovery investments can be performed manually using locally relevant tariffs and emission factors.
The Part 1–3 tasks, prompts, and assessment suggestions below remain fully valid regardless of the chosen platform, ensuring flexibility and accessibility across different teaching contexts.
Educator support and implementation notes:
The activity is designed to be delivered across 3 sessions (6–7.5 hours total), with flexibility to adapt based on depth of exploration, simulation familiarity, or group size. Each part can be run as a standalone module or integrated sequentially in a capstone-style format.
Part 1: System mapping: (Time: 2 to 2.5 hours) – Ideal for a classroom session with blended instruction and group collaboration:
This stage introduces students to the foundational step of any heat integration analysis: system mapping. The aim is to identify and represent energy-carrying streams in a process plant, laying the groundwork for further system analysis. Educators may use the Process Flow Diagram of Fig. 1, Appendix A (from a real industrial setting: a food processing plant) or another Process Diagram, real or fictional. Students shall extract and identify thermal energy streams (hot/cold) within the system boundary and map energy balances before engaging with software to produce required simulation outputs.
Key activities and concepts include:
Defining system boundaries: Focus solely on thermal energy streams, ignoring non-thermal operations. The boundary is drawn from heat sources (hot streams) to heat sinks (cold streams).
Identifying hot and cold streams: Students classify process material streams based on whether they release or require heat. Each stream is defined by its inlet and target temperatures and its heat capacity flow rate (CP).
Building the stream table: Students compile a simple table of hot/cold streams (name, supply temperature, target temperature and heat capacity flow CP).
Constructing energy balances and Sankey Diagrams: Students manually calculate energy balances across each subsystem in the defined system boundary, identifying energy inputs, useful heat recovery, and losses. Using this information, they construct Sankey diagrams to visualise the magnitude and direction of energy flows, strengthening their grasp of system-wide energy performance before optimisation.
Pinch Concept introduction: Students are introduced to the concept of “the Pinch”, including the minimum heat exchanger temperature difference (ΔTmin) and how it affects heat recovery targets (QREC), as well as overall heating and cooling utility demands (QHU & QCU, respectively).
Assumptions: All analysis is conducted under steady-state conditions with constant CP and no heat losses.
Discussion prompts:
What insights does the Sankey diagram reveal about energy use, waste and recovery potential in the system? How might these visual insights shape optimisation decisions?
Why might certain streams be excluded from the analysis?
How does the choice of ΔTmin influence the heat recovery potential and cost?
What trade-offs are involved in system simplification during mapping?
How can assumptions (like steady-state vs. transient) impact integration outcomes?
Student deliverables:
A labelled system map showing the thermal process boundaries, hot and cold streams.
A structured stream data table.
Justification for selected ΔTmin values based on process safety, economics, or practical design and operational considerations.
A basic Sankey diagram representing the energy flows in the mapped system, based on calculated heat duties of each stream.
Part 2: Running and interpreting process system simulation results (Time: 2 to 2.5 hours) – Suitable for lab or flipped delivery;only standard computer access is needed to run the tool (optional instructor demo can extend depth):
Students use the simulation tool to generate their own results.The process scenario of Fig. 1, Appendix A, with the associated stream data (Table 1) can be used as a baseline.
Tool-generated outputs:
Curves: Composite and Grand Composite (pinch location, recovery potential).
Scenario summary: QREC, QHU, QCU; COP (where applicable); CAPEX/OPEX/CO₂; payback period for various values of system levers (e.g., ΔTmin levels, tariffs, emission factors).
Heat Pump (HP) tables: Feasible pairs, Top-N heat pump selections (where N = 0, 1, or 2); QEVAP, QCOND, QCOMP, COP. All notations are designated in the simulator’s help/README section.
Learning tasks:
1. Scenario sweeps Run different scenarios (e.g., different ΔTmin levels, tariffs, emission factors, and Top-N HP selections). Prompts: How do QREC, QHU/QCU, HX area, and CAPEX/OPEX/CO₂ shift across scenarios? Which lever moves the needle most?
2. Group contrast (cases A vs B: see time-phased operations A & B in Appendix A) Assign groups different cases; each reports system behaviours and trade-offs. Prompts: Where do you see CAPEX vs. energy-recovery tension? Which case is more HP-friendly and why?
3. Curve reading Use the Composite & Grand Composite Curves to identify pinch points and bottlenecks; link features on the curves to the tabulated results. Prompts: Where is the pinch? How does ΔTmin change the heat-recovery target and utility demands?
4. Downstream implications Trace how curve-level insights show up in HX sizing/costs and HP options. Prompts: When does adding HP reduce utilities vs. just shifting costs? Where do stream temperatures/CP constrain integration?
5. Systems lens: feedback and leverage Map short causal chains from the results (e.g., tariffs → HP use → electricity cost → OPEX; grid-carbon → HP emissions → net CO₂). Prompts: Which levers (ΔTmin, tariffs, EFs, Top-N) create reinforcing or balancing effects?
Outcome:
Students will be able to generate and interpret industrial simulation outputs, linking technical findings to economic and emissions consequences through a systems-thinking lens. They begin by tracing simple cause–effect chains from the simulation data and progressively translate these into causal loop diagrams (CLDs) that visualise reinforcing and balancing feedback. Through this, learners develop the ability to explain how system structure drives performance both within the plant and across its broader industrial and policy environment.
Optional extension: Educators may provide 2–3 predefined subsystem options (e.g., low-CAPEX HX network, high-COP HP integration, hybrid retrofit) for comparison. Students can use a decision matrix to justify their chosen configuration against CAPEX, OPEX, emissions, and controllability trade-offs.
Part 3: Systems thinking through scenario analysis (Time: 2 to 2.5 hours) – Benefits from larger-group facilitation, a whiteboard or Miro board (optional), and open discussion. It is rich in systems pedagogy:
Having completed simulation-based pinch analysis and heat recovery planning, learners now shift focus to strategic implementation challenges faced in real-world industrial settings. In this part, students apply systems thinking to explore the broader implications of their heat integration simulation output scenarios, moving beyond process optimisation to consider real-world dynamics, trade-offs, and stakeholder interactions. The goal is to encourage students to interrogate the interconnectedness of decisions, feedback loops, and unintended consequences in process energy systems including but not limited to operational complexity, resilience to disruptions, and alignment with long-term sustainability goals.
Activity: Stakeholder role play / Multi-Criteria Decision Analysis Students take on stakeholder roles and debate which design variant or operating strategy should be prioritised. They then conduct a Multi-Criteria Decision Analysis (MCDA), evaluating each option based on criteria such as CAPEX, OPEX savings, emissions reductions, risk, and operational ease.
Stakeholders include:
Operations managers, focused on ease of control and process stability.
Investors and finance teams, focused on return on investment.
Environmental officers, concerned with emissions and policy compliance.
Engineers, responsible for design and retrofitting.
Community members, advocating for sustainable industry practices.
Government reps responsible for regulations and policy formulation, e.g. taxes and subsides.
The team must present a strategic analysis showing how the heat recovery system behaves as a complex adaptive system, and how its implementation can be optimised to balance technical, financial, environmental, and human considerations.
Optional STOP for questions and activities:
Before constructing causal loop diagrams (CLDs), learners revisit key results from their simulation — such as ΔTmin, tariffs, emission factors, and system costs — and trace how these parameters interact to influence overall system performance. Educators guide this transition, helping students abstract quantitative outputs (e.g., changes in QREC, OPEX, or CO₂) into qualitative feedback relationships that reveal cause-and-effect chains. This scaffolding helps bridge the gap between process simulation and systems-thinking representation, supporting discovery of reinforcing and balancing feedback structures.
Activity: Construct a causal loop diagram (CLD) Students identify at least five variables that interact dynamically in the implementation of a heat integration system (e.g. energy cost, investment risk, emissions savings, system complexity, staff training). They must map reinforcing and balancing feedback loops that illustrate trade-offs or virtuous cycles.
Where could policy or process changes trigger leverage points?
How could delays in response (e.g. slow staff adaptation to new technologies) affect outcomes?
How might design choices affect local energy equity, air quality, or community outcomes?
What policy incentives or ethical trade-offs might reinforce or hinder your proposed solution?
Instructor debrief (engineering context with simulation linkage): After students share their CLDs, the educator facilitates a short discussion linking their identified reinforcing and balancing loops to common dynamic patterns observable in the simulation results. For instance:
Limits to growth: As ΔTmin decreases, heat recovery (QREC) initially improves, but exchanger area, CAPEX, and controllability demands grow disproportionately — diminishing overall economic benefit.
Shifting the burden: Installing a heat pump may appear to improve carbon performance, but if low process efficiency remains unaddressed, electricity use and OPEX rise — creating a new dependency that shifts rather than solves the problem.
Tragedy of the commons: Competing units or stakeholders optimising locally (e.g. for their own OPEX or production uptime) can undermine total system efficiency or resilience.
Success to the successful: Design options with early financial or policy support (e.g. high-COP heat pumps) attract more investment and attention, reinforcing a positive but unequal feedback loop.
This reflection connects quantitative model outputs (e.g. QREC, OPEX, CAPEX, emissions) to qualitative system behaviours, helping learners recognise leverage points and understand how design choices interact across technical, economic, and social dimensions of decarbonisation.
Activity: Explore “What if?” scenarios
Working in groups, students choose one scenario to explore using a systems lens:
What if gas prices fluctuate drastically?
What if capital funding is delayed by 6 months?
What if a heat exchanger fouls during peak season?
What if CO₂ emissions policy tightens?
What if current electricity grid decarbonisation trends suffer an unexpected setback?
What if government policies now encourage onsite renewable electricity generation?
Each group evaluates the resilience and flexibility of the proposed integration design. They consider:
System bottlenecks and fragilities.
Leverage points for intervention.
Need for redundancy or modular design.
Educators may add advanced scenarios (e.g. carbon tax introduction, supplier failure, or project delay) to challenge students’ resilience modelling and stakeholder negotiation skills.
Stakeholder impact reflection:
To extend systems reasoning beyond the technical domain, students assess how their chosen design scenarios (e.g., low vs. high ΔTmin, with or without heat pump integration) affect each stakeholder group. For instance:
Operations managers assess control complexity, downtime risk, and maintenance implications.
Finance teams evaluate CAPEX/OPEX trade-offs and payback periods.
Environmental officers examine lifecycle emissions and regulatory compliance.
Engineers reflect on reliability, retrofit feasibility, and process safety.
Community members or regulators consider social and policy outcomes, such as visible sustainability impact or energy equity.
Each team member rates perceived benefits, risks, or compromises under each design case, and the results are summarised in a stakeholder impact matrix or discussion table. This exercise links quantitative system metrics (energy recovery, emissions, cost) to qualitative stakeholder outcomes, reinforcing the “multi-layered feedback” perspective central to complex systems analysis.
Learning Outcomes (Part 3):
By the end of this part, students will be able to:
Identify systemic interdependencies in industrial energy systems.
Analyse how feedback loops and delays influence system behaviour.
Assess the resilience of energy integration solutions under different future scenarios.
Balance multiple stakeholder objectives in complex engineering contexts.
Apply systems thinking tools to communicate complex technical scenarios to diverse stakeholder audiences.
Use systems diagrams and decision tools to support strategic analysis.
Instructor Note – Guiding CLD and archetype exploration:
Moving from numerical heat-exchange and cost data to CLD archetypes can be conceptually challenging. Instructors are encouraged to model this process by identifying at least one reinforcing loop (e.g. “energy savings → lower OPEX → more investment in recovery → further savings”) and one balancing loop (e.g. “higher capital cost → reduced investment → lower heat recovery”). Relating these loops to common system archetypes such as “Limits to Growth” or “Balancing with Delay” helps students connect engineering data to broader system dynamics and locate potential leverage points. The activity concludes with students synthesising their findings from simulation, systems mapping, and stakeholder analysis into a coherent reflection on complex system behaviour and sustainable design trade-offs.
Assessment guidance:
This assessment builds directly on the simulation and systems-thinking activities completed by students. Learners generate and interpret their own simulation outputs (or equivalent open-source pinch analysis results), using these to justify engineering and strategic decisions under uncertainty.
Assessment focuses on students’ ability to integrate quantitative analysis (energy, cost, carbon) with qualitative reasoning (feedbacks, trade-offs, stakeholder dynamics), demonstrating holistic systems understanding.
Deliverables (portfolio; individual or group):
1. Reading and interpretation of simulation outputs
Use the outputs you generate (composite & grand composite curves: HX match/area/cost tables; HP pairing/ranking; summary sheets of QHU, QCU, QREC, COP, CAPEX, OPEX, CO₂, paybacks) for a different industrial process (from the one used in the main learning activity) to:
Identify the pinch point(s) and explain what the curves imply for recovery potential and bottlenecks.
Comment on QHU/QCU/QREC and how they change across the scenarios you run (e.g., ΔTmin, tariffs, emission factors, Top-N HP selection).
Interpret trade-offs among energy, CAPEX, OPEX, emissions, using numbers reported by the simulator. No calculations beyond light arithmetic/annotation.
2. Systems mapping and scenario reasoning
A concise system boundary sketch and a simple stream table.
A Causal Loop Diagram (CLD) highlighting key feedbacks (e.g., tariffs ↔ HP use ↔ grid carbon intensity ↔ emissions/cost).
A short MCDA (transparent criteria/weights) comparing the scenario variants you test; include a brief stakeholder reflection.
3. Decision memo (max 2 pages)
Your recommended integration option under stated assumptions, with one “what-if” sensitivity (e.g., +20% electricity price, tighter CO₂ factor).
State uncertainties/assumptions and any implementation risks (operations, fouling, timing of capital).
Students should include a short reflective note addressing assumptions, feedback insights, and how their stakeholder perspective shaped their recommendation.
Appendix A: Example process scenario for teaching activity:
Sample narrative: Large-scale food processing plant with time-sliced operations
The following process scenario explains the industrial context behind the main teaching activity simulations. A large-scale food processing plant operates a milk product manufacturing line. The process, part of which is shown in Fig. 1, involves the following:
Thermal evaporation of milk feed.
Cooking operations after other ingredient mixing and formulation upstream.
Oven heating to drive off moisture and stimulate critical product attributes.
Pre-finishing operations as the product approaches packaging.
In real operations, the evaporation subprocessoccurs at different times from the cooking/separation, oven and pre-finishing operations. This means that their hot and cold process streams are not simultaneously available for direct heat exchange. For a realistic industrial pinch analysis, the process is thus split into two time slices:
Time Slice A (used for scenario Case A): Evaporation streams only.
Time Slice B (Case B): Cooking/separation, oven and pre-finishing streams only.
Separate pinch analyses are performed for each slice, using the yellow-highlighted sections of Table 1 as stream data for time slice A, and the green-highlighted sections as stream data for time slice B. Any heat recovery between slices would require thermal storage (e.g., a hot-water tank) to bridge the time gap.
Fig.1. Simplified process flowsheet of food manufacturing facility.
Note on storage and system boundaries:
Because the two sub-processes occur at different times, direct process-to-process heat exchange between their streams is not possible without thermal storage. If storage is introduced:
Production surplus heat at time slice A can be stored at high temperature (e.g., 80 °C) and later discharged to preheat time slice B cold streams.
The size of the tank depends on the portion of hot utility demand of sub-process B to be offset, the temperature swing, and the duration of the sub-process B.
Table 1. Process stream data corresponding to flowsheet of Fig. 1. Yellow-highlighted sections represent processes available at time slice A, while green-highlighted sections are processes available at time slice B.
Appendix B: Suggested marking rubric (Editable):
Adopter note: The rubric below is a suggested template. Instructors may adjust criteria language, weightings and band thresholds to align with local policies and learning outcomes. No marks depend on running software.
1) Interpretation of Simulation Outputs — 25%
A (Excellent): Reads curves/tables correctly; uses QHU/QCU/QREC, COP, CAPEX/OPEX/CO₂, payback figures accurately; draws clear, defensible trade-offs.
B (Good): Mostly accurate; links numbers to decisions with some insight.
C (Adequate): Mixed accuracy; limited or generic trade-off discussion.
D/F (Weak): Frequent misreads; cherry-picks or contradicts generated data.
2) Systems Thinking & Scenario Analysis — 30%
A: Clear CLD with at least one reinforcing and one balancing loop; leverage points identified; scenarios coherent; MCDA with explicit criteria, weights, and justified ranking; uncertainty acknowledged.
B: Reasonable CLD; scenarios sound; MCDA present with partial justification.
C: Superficial CLD; scenarios/MCDA incomplete or weakly reasoned.
D/F: Little or no systems view; scenarios/MCDA absent or not meaningful.
Atuonwu, J.C. (2025). A Simulation Tool for Pinch Analysis and Heat Exchanger/Heat Pump Integration in Industrial Processes: Development and Application in Challenge-based Learning. Education for Chemical Engineers 52, 141-150.
Oh, X.B., Rozali, N.E.M., Liew, P.Y., Klemes, J.J. (2021). Design of integrated energy- water systems using Pinch Analysis: a nexus study of energy-water-carbon emissions. Journal of Cleaner Production 322, 129092.
Rosenow, J., Arpagaus, C., Lechtenböhmer, S.,Oxenaar, S., Pusceddu, E. (2025). The heat is on: Policy solutions for industrial electrification. Energy Research & Social Science 127, 104227.
Bale, C.S.E., Varga, L., Foxon, T.J. (2015). Energy and complexity: New ways forward. Applied Energy 138, 150-159.
Atuonwu, J.C. (2025). Proprietary Simulator for Pinch Analysis & Heat Integration. Private reviewer access available on request (demo video or temporary login).
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Licensing:This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License. It was originally developed as part of the Strathclyde Climate Ambassadors Networks (StrathCAN) at Strathclyde in collaboration with the Centre for Sustainable Development.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, and Critical Thinking INCOSE Competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4):Integrated / Systems Approach (essential to the solution of broadly-defined problems), Problem analysis, Sustainability, and Science, mathematics, and engineering principles.
Educational level: Beginner.
Learning and teaching notes:
The two complementary workshops, Climate Fresk and En-ROADS, are introduced to situate Renewable Energy Technologies within the wider context of the Net Zero transition. Their purpose is first to deepen students’ understanding of the climate science that underpins climate change as the driver of technical innovation, and then to broaden awareness of the social, economic, political, and environmental factors that shape global decarbonisation pathways. Building on this foundation, the workshops shift focus to the policy levers required to enable systems change – highlighting, often with surprising insights, their relative effectiveness in reducing emissions and limiting temperature rise. Together, they provide the context for a Renewable Energy Technologies module, where attention turns to the role of renewables and other low-carbon technologies as climate solutions. The central takeaway is that there is no single “silver bullet” solution; instead, a coordinated “silver buckshot” approach is essential.
Learners do not require any prior learning in the area of climate change or climate solutions for these workshops. The workshops are the perfect introduction to these. Climate Fresk facilitator training begins with attending a workshop as a participant, followed by a session on facilitation. Staff can train via local workshops, the CF MOOC and peer-to-peer practice, or through official training, enabling institutions to build a self-sustaining community of facilitators at minimal cost.
Learners have the opportunity to:
Learn about the climate science that underpins the IPCC assessment reports.
Develop an understanding of systems thinking by applying it to climate science and the impacts of climate change, while also exploring the policy solutions needed to drive systems-level change.
Be Introduced to the En-Roads Climate Simulator tool and the possibility of becoming trained Climate Fresk Facilitators themselves.
Teachers have the opportunity to:
Actively engage the students in taking a systems thinking approach to their understanding of ‘the problem’ of climate change, and exploring ‘the solutions’ to it.
Use these workshops as stand-alone activities (for outreach) or embed within the curriculum.
Collaborate with other teachers and students, by training them as facilitators to support future workshops.
Engage students with different competencies such as systems thinking, critical thinking, and anticipatory thinking and highlight to students how these are relevant and applied.
Downloads: A PDF of this resource will be available soon.
This activity utilises off-the-shelf educational tools in the form of the Climate Fresk workshop and the En-Roads Climate Simulator tool. These are used in two separate (but connected) workshops adapted from the guided assignment that is presented in the resources above. These are not intended to be run back-to-back. In fact, some gap (of days) in between is desirable as together, this would be too exhausting, and also give time for reflection in between.
The Climate Fresk workshop is designed to build a solid understanding of cause-and-effect in climate systems. This develops baseline systems thinking without overloading students.
En-ROADS, is designed to engage students with the types of sectors that we need to decarbonise and get them thinking about the need for system wide policies to achieve system wide decarbonisation of our energy system.
Figure 1. Using Climate Fresk and En-ROADS as complementary workshops focusing on ‘the climate problem’ and ‘climate solutions’.
A key aspect of both workshops is highlighting the need for systems thinking in both understanding the problem of, and exploring the solutions to, climate change. This involves introducing students to the cause and effects of climate change, feedback loops and the concept of tipping points – both in terms of climate tipping points (BBC Sounds – The Climate Tipping Points, no date) that can potentially trigger irreversible changes in the climate system, as well as positive, social tipping points (TEDx Talks 2023) that once crossed can shift social norms, and how policies can affect this. It allows discussions around leverage points in the context of climate solutions and policies, which Donella Meadows describes as where “a small shift in one thing can produce big changes in everything”.
Part one: Climate Fresk workshop:Understanding the problem of climate change (or the ‘science piece’):
Overview:
Climate Fresk is a 2-2.5 hour facilitator-led gamified workshop based on the latest IPCC report, where participants work in groups to build a causal-loop diagram (or fresk) of the Earth’s climate system using specially designed cards. The activity encourages discussion, challenges assumptions, and develops systems thinking by illustrating the interconnections, feedback loops, and tipping points of climate change. In doing so, it supports UNESCO Education for Sustainable Development competencies in anticipatory and systems thinking, helping participants understand the potential impacts of climate dynamics on ecological, social, and economic systems in a way that is accessible.
Scalability and setup:
The Climate Fresk workshop can be delivered to almost any number of participants, limited only by the size of the space, the number of trained facilitators available, and the number of card decks. Participants are usually divided into groups of 8 (10 at a push), each working around a table roughly 2m x 1m in size. Each group (table) requires a dedicated facilitator to guide the process.
Facilitation and training:
Facilitators must be trained before running the activity. Training can be undertaken through official Climate Fresk courses (see resources) or, once enough experience has been built, in-house peer-to-peer training supported by staff development units. Facilitators use a “crib sheet” containing guiding questions and timings to help keep groups on track.
Workshop materials:
The Fresk uses a deck of 42 cards, each representing a cause, effect, or impact within the climate system-ranging from fossil fuel use across industry, buildings, transport and agriculture, to wider impacts on society, biodiversity, and ecosystems. Each card has a graphic on one side and explanatory text on the other, which participants use to determine its role in the system.
Learning process:
Over the session, participants collaboratively arrange the cards on a large sheet of paper to construct a causal-loop diagram of the climate system. In doing so, they identify drivers of carbon emissions, critical carbon sinks, feedback loops, and potential tipping points. The activity encourages discussion, challenges assumptions, and introduces key climate science terminology, while making visible the complex interdependencies of Earth systems.
Reflection and discussion:
After constructing the Fresk, participants are encouraged to reflect on how the process made them feel (normative competency) and what insights they gained. This is followed by open discussion on mitigation strategies and possible solutions. In a standard Climate Fresk workshop, around 45 minutes is devoted to this. However, when combined with the En-Roads simulator, this discussion naturally transitions from the “problem space” of the Fresk workshop to the “solutions space” of the subsequent En-Roads workshop, where participants explore the realistic impacts of different climate solutions, their co-benefits, and the equity issues they raise – engaging participants in deeper systems-level thinking.
Part two: En-ROADS workshop:‘Exploring the solutions’ to climate change (or the ‘policy piece’):
Overview:
This En-ROADS workshop can be run from one to two hours, and can follow a role-play format, where participants are asked to take on the role of policymakers, exploring different policy options to limit global temperatures to 1.5oC (or 2oC). They are introduced to the workshop by telling them “you are policymakers tasked with limiting global heating”. En-Roads is a climate change simulator developed by Climate Interactive and MIT that uses roleplay to explore global policy interventions for limiting temperature rise. It enables participants—from students to policymakers—to test combinations of climate solutions, examine trade-offs and unintended consequences, and understand that no single “silver bullet” exists. The workshop develops UNESCO Education for Sustainable Development competencies in anticipatory, systems, critical, and strategic thinking, while highlighting the challenges of achieving policy consensus across diverse stakeholders.
Preparation:
1. Participants
Suitable for classes split into small groups.
Works well in groups of 3–5 for discussions.
2. Facilitators
1 facilitator to introduce the tool and guide reflection.
Teaching assistants can circulate during group tasks to prompt discussion.
Handouts: list of possible climate “levers” (policy actions) – See resources – En-Roads Control Panel
Online polling software (e.g. Mentimeter)
Step-by-step instructions for 60-minute workshop (but can be expanded to 2 hours involving more discussion and more interaction with En-Roads simulator):
1. Introduction (5 mins)
Introduce EN-ROADS as an interactive simulator for testing climate solutions.
Explain the goal: Can we keep global heating below 1.5 °C?
Use causal loop diagram below to demonstrate how mitigating actions effect positive change.
Figure 2. Causal loop diagram showing how increasing GHG emissions drive climate action and emissions reduction.
2. Initial actions brainstorm (5 mins)
Ask cohort to use an online polling system, asking them to vote for their Topaction (from the list of mitigating actions – see resources – En-Roads Control Panel) that that they think will have the greatest impact on reducing emissions and temperature.
Figure 3. Example of a Menti poll to capture learners’ understanding of climate solution impacts.
Don’t show this yet – keep this for later, when you will ask them to vote again and can then compare how their views have changed from beginning to end of session.
Ask participants to self-sort into groups of 3–4, and now ask them to discuss what their Top 3 actions would be – they must agree on these.
3.Using EN-ROADS (15 mins)
As facilitator, ask one group to volunteer their top action. Demonstrate their action using the simulator with an example (e.g. applying a coal phase-out or carbon tax).
IMPORTANT: Before you implement the action – ask the group (and others) what they expect to happen to emissions and temperature.
Apply their action and ask if it is what they expected. Then discuss why it is, or is not, what they expected to see.
Highlight unintended consequences (e.g. rising energy prices and discussion on the real-world impacts this can have on local communities or households, land-use impacts).
This does require the facilitator to be familiar with the simulator and what these impacts might be and how to use the simulator to show these (there is a Climate Interactive course available (Training, no date), which is free, and there are also many resources available for individuals to work through at their own pace).
Can repeat this with other groups volunteering their top action. Ask for a group who has a different top action, or ask a group for their second top action to ensure you cover different levers.
4. Group simulation (15 mins)
Ask groups to now use En-Roads to consider other levers to get temperature as close to 1.5oC as possible, to determine whether their initial top 5 ranking has changed.
They should record how much each action reduces emissions and temperature rise.
Take the poll again.
Show both polls and look at differences – have they changed their views on certain actions – ask them why.
Discuss: Which actions had the biggest effect? Which had less than expected? Why?
5. Achieving 1.5 °C (10 mins)
Ask who reached 1.5oC
Ask them to show their combined actions.
Open up for discussion on how feasible these actions look – what are the implementation challenges associated with them. Are there risks of unintended consequences such as GDP, equity, biodiversity, etc?
6. Reflection and debrief (5 mins)
Discuss key takeaways:
The importance of combining multiple actions (“silver buckshot” rather than a silver bullet).
Trade-offs and co-benefits (e.g. health, equity, biodiversity).
The role (and challenge) of collaboration and consensus in policy decisions.
7. Post Workshop – optional
Challenge groups to adjust policies and combinations of levers to approach the IEA’s Net Zero 2050 (1.5 °C) pathway, and compare their pathways with this. Gives them a sense of how challenging/possible the net-zero pathway will be.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Downloads: A PDF of this resource will be available soon.
Who is this article for?: Thisarticle should be read by educators at all levels in higher education who are seeking an overall perspective on teaching approaches for integrating complex systems in engineering education.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking and Critical Thinking INCOSE competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems).
Premise:
Engineering education is undergoing a fundamental transformation. The convergence of technological, social, and environmental challenges demands that future engineers move beyond procedural problem-solving toward complex thinking – a mindset capable of navigating uncertainty, interdependence, and dynamic change. This shift has been accelerated by advances in Artificial Intelligence (AI), which have redefined both the nature of engineering practice and the competencies students must develop to thrive in it.
For scientists and engineers, understanding complex systems is critical for the ability to apply knowledge and techniques across diverse contexts. This is particularly visible in fields such as bioengineering, which depends on advances in chemistry, physics, computing, and other engineering disciplines. Such integration requires designing subsystems where engineering expertise can be meaningfully applied. Complex systems also involve human interaction, introducing unpredictability, feedback loops, and uncertainty. Modern AI-enabled systems—ranging from autonomous vehicles to smart grids and biomedical devices—cannot be fully understood through a single traditional discipline. These systems are not simply complicated; they are interconnected, dynamic, and often nonlinear (Jakobsson, 2025).
What this means for engineering education and educators:
Across the globe, educators have turned to Problem-Based Learning (PBL) as a central strategy for cultivating systems-oriented thinking. For instance, Tauro et al. (2017) and the case study conducted at Tishk International University demonstrate that integrating PBL within mechatronics education enhances students’ ability to connect theory with practice, encouraging collaboration and creativity in addressing multifaceted engineering problems. Similarly, Watters et al. (2016) show that industry–school partnerships transform classrooms into real-world laboratories, reinforcing the value of experiential learning and knowledge transfer between academia and professional practice. These initiatives reflect a broader movement toward authentic, interdisciplinary engagement, a necessary foundation for understanding and designing complex systems.
However, adopting PBL and interdisciplinary methods is not only a pedagogical improvement but also an epistemological necessity. As Stegeager et al. (2024) emphasise, educators themselves must evolve from instructors to facilitators, cultivating reflective and adaptive learning environments that mirror the complexity of professional engineering contexts. Mynderse et al. further highlight that when students are given responsibility for solving open-ended problems, they report higher satisfaction and deeper conceptual integration. These outcomes suggest that active learning approaches foster the kind of complex, interconnected reasoning required for contemporary engineering practice.
In parallel, the AI-driven classroom is transforming the educational landscape. Emerging evidence shows that generative AI tools support personalised learning and immediate feedback, freeing educators to focus on mentorship and creativity (Jaramillo, 2024). Yet this technological advancement also underscores the limits of automation. Machines can model and predict, but they cannot interpret ethical implications, reconcile trade-offs, or integrate human and ecological perspectives. This is where complex thinking becomes indispensable: it enables learners to understand AI not merely as a computational tool but as a component within broader sociotechnical systems.
The need for complex systems understanding is especially acute in fields such as bioengineering and mechatronics, where technologies intersect with living systems and social contexts. The defining feature of complex systems is the interaction among multiple components that produce emergent, often unpredictable behaviour. For engineering students, grasping these principles means developing the ability to think beyond linear causality and to engage with feedback loops, uncertainty, and adaptive design.
The imperative to transform engineering education:
In traditional engineering education, students get topics presented in discrete classes. They get trained in thermodynamics and fluid mechanics and they often forget what they have learned by the time they are at the control systems course where there is an opportunity to bring together skills from prior knowledge. This modularised model is already losing its effectiveness in preparing the students for encountering real-world problems. As the adage says, “In theory, theory and practice are the same; in practice, they are not”. Understanding the role of noise, measurement errors, simplifying assumptions and computational errors play an essential role. To this end, it is crucial to centre complex system design and embrace interdisciplinarity to develop a competency that supports life-long, adaptive learning.
As an example, Aalborg University in Denmark stands as a global exemplary of systems-oriented engineering education. Its PBL model is not an add-on; it is the spine of the entire curriculum. Every semester, students tackle a new problem – often tied to societal needs such as urban planning, environmental sustainability, or healthcare. Students must identify relevant knowledge areas, work collaboratively across disciplines, and reflect on both process and outcome. Faculty report that this structure promotes holistic thinking, resilience, and a sense of professional identity early on the students’ journeys (Kolmos et al. 2008).
On the undergraduate level, capstones are a common part of engineering education which happens at the late stages of the student’s studies. At Rowan University (New Jersey, USA), Engineering Clinics provide a different but equally powerful model. Students work across all four years on interdisciplinary teams, contributing to faculty research or industry-sponsored projects. These clinics are embedded in the curriculum and require students to engage deeply with current research problems, often involving complex technical and human systems. A junior clinic project, for example, might involve the optimisation of a renewable energy system integrating mechanical, electrical, and computer engineering principles. Therefore, students learn to navigate ambiguity, collaborate with experts, and see the relevance of their disciplinary knowledge in a broader context by confronting the messy nature of real data.
These are two of many examples where systems thinking is cultivated. Students gain exposure to open-ended problems and practice seeking connection across domains as they encounter the limits of their knowledge. In this fast-moving era, crossing disciplines empowers students for lifelong adaptation, allowing them to incorporate their experiences into any new technological developments. It also encourages treating learning as a collaborative social process, rather than a solo race to secure the first job.
Educators must do more than just deliver content; they also need to act as facilitators and learn alongside their students. By redesigning the curriculum around design-oriented problems that mirror real-world changes, higher education will better prepare future engineers to face upcoming systemic global challenges.
Looking ahead:
As artificial intelligence and automation continue to reshape industry, engineering education must also evolve. Integrating complex systems into teaching offers students the opportunity to engage directly with the data-driven ecosystem they will encounter in practice. The goal is not only to produce technically skilled engineers, but also thoughtful stewards of technology who can navigate its broader social and ethical dimensions.
One ongoing challenge is that independent projects often vary in quality and can be difficult to assess. Without intentional design, students may default to trial-and-error approaches instead of drawing on knowledge from prior courses. At the same time, the pressure to cover extensive technical material can make it difficult to provide the broader systems context essential for modern engineering. Yet when learning is reinforced across the curriculum, students are better prepared for future careers that demand systems-based thinking.
Experiential, self-directed projects play a crucial role in this preparation. They allow students to choose their own path while working closely with advisors and industry partners. Whether developing a product, designing a system, or engaging with professionals, students gain a perspective that feels different from traditional coursework. This process offers them a glimpse of what it means to think and act like real engineers, fostering both confidence and adaptability as they transition from the classroom to the workplace.
References:
Jakobsson, Eric et al. (1999) ‘Complex systems: Why and what?’, New England Complex Systems Institute. Available at: https://necsi.edu/complex-systems-why-and-what (Accessed: 16 July 2025).
Stegeager, N., Traulsen, S., Carvalho Guerra, A., Telléus, P., Du, X. (2024) ‘Do good intentions lead to expected outcomes? Professional learning amongst early career academics in a problem-based program’, Education Sciences, 14(2), p. 205. Available at: https://doi.org/10.3390/educsci14020205.
Tauro, F., Cha, Y., Rahim, F., Rasul, M.S., Osman, K., Halim, L., Dennisur, D., Esner, B., Porfiri, M. (2017) ‘Integrating mechatronics in project-based learning of Malaysian high school students and teachers’, International Journal of Mechanical Engineering Education. Available at: https://journals.sagepub.com/doi/full/10.1177/0306419017708636 (Accessed: 1 August 2025).
Watters, J., Pillay, H. and Flynn, M. (2016) ‘Industry-school partnerships: A strategy to enhance education and training opportunities. Australia’, Queensland University of Technology. Available at: https://eprints.qut.edu.au/98390/ (Accessed: 30 July 2025).
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, Requirements Definition, Communication, Design For, and Critical Thinking INCOSE Competencies.
AHEP4 mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems). In addition, this resource addresses the themes of Sustainability and Communication.
Educational level: Beginner; intermediate.
Acknowledgement:
The case study underpinning this teaching activity was developed by Prof. Kristen MacAskill (University of Cambridge). The Module was first developed and implemented in teaching by TEDI- London, led by a team of learning technologists, Ellie Bates, Laurence Chater, Pratishtha Poudel, and academic member, Rhythima Shinde. This work was carried out in collaboration with the Royal Academy of Engineering through its Engineering X programme — a global partnership that supports safer, more sustainable engineering education and practice worldwide. With critical support from Professor Kristen MacAskill and involvement of Ana Andrade and Hazel Ingham, Aisha Seif Salim. This was a collective effort involving many individuals across TEDI-London and RAEng (advisors and reviewers), and while we cannot name everyone here, we are deeply grateful for all the contributions that made this module possible.
Learning and teaching notes:
This case study introduces a structured, systems-thinking–based teaching resource. It provides educators with tools and frameworks—such as the Cynefin framework and stakeholder mapping—to analyse and interpret complex socio-technical challenges. By exploring the case of the Queensland, Australia floods, it demonstrates how engineering decisions evolve within interconnected technical and social systems, helping students link theory with practice.
The Cynefin framework (Nachbagauer, 2021; Snowden, 2002), helps decision-makers distinguish between different types of problem contexts—simple, complicated, complex, chaotic, and disordered. In an engineering context, this framework guides learners to recognise when traditional linear methods work (for simple or complicated problems) and when adaptive, experimental approaches are required (for complex or chaotic systems).
Within this teaching activity, Cynefin is used to help students understand how resilience strategies evolve when facing uncertainty, incomplete information, and changing stakeholder dynamics. By mapping case study events to the Cynefin domains, learners gain a structured way to navigate uncertainty and identify appropriate modes of action.
This case study activity assumes basic familiarity with systems concepts and builds on this foundation with deeper application to real-world socio-technical challenges.
Summary of context:
The activity focuses on a case study of 2010–2011 floods in Queensland, Australia, which caused extensive damage to urban infrastructure. The Queensland Reconstruction Authority (QRA) initially directed resources to short-term asset repairs but subsequently shifted towards long-term resilience planning, hazard management, and community-centred approaches.
The case resonates with global engineering challenges, such as flood, fire, and storm resilience, and can be easily adapted to local contexts. This case therefore connects systems thinking theory directly to engineering and governance decisions, illustrating how frameworks like Cynefin can support engineers in navigating uncertainty across technical and institutional domains.
Learning objectives:
Aligned with AHEP4 (Engineering Council, 2020) – Outcomes 6, 10, and 16 on systems approaches, sustainability, and risk – this activity emphasises systems thinking, stakeholder engagement, problem definition, and decision-making under uncertainty.
This teaching activity introduces learners to the principles and practice of systems thinking by embedding a real-world case study into engineering education (Godfrey et al., 2014; Monat et al.,2022). The objectives are to:
Enable students to recognise interconnections, interdependencies, and evolving behaviours of stakeholders within socio-technical systems.
Support learners in applying systems frameworks —particularly the Cynefin framework and stakeholder mapping—to analyse complexity, uncertainty, and decision-making in climate resilience and disaster mitigation contexts.
Apply systems thinking tools and frameworks to real-world challenges, such as climate resilience and disaster mitigation.
Strengthen confidence in addressing uncertainty and complexity in engineering problem-solving.
Collaborate effectively across diverse teams, appreciating multiple stakeholder perspectives.
Reflect critically on trade-offs and decision-making in engineering practice.
Equip students to transfer systems insights from case-based scenarios to broader projects in their curriculum and future professional practice.
Teachers have the opportunity to:
Introduce students to complex systems concepts through engaging, real-world case studies.
Facilitate interactive, blended learning using narrative-driven tools, explainer animations, and role-play exercises.
Assess learners’ baseline and improved understanding of systems thinking through pre- and post-module surveys.
Guide students in navigating multiple systems frameworks while managing cognitive load.
Encourage interdisciplinary collaboration and stakeholder-focused analysis within classroom or project-based settings.
Adapt and scale the teaching activity for different educational levels, contexts, and case study themes (e.g., floods, wildfires, extreme heat).
This dedicated platform hosts the interactive modules designed for this teaching activity. Students progress through three modules — Context, Analysis and Insights, and Discussion and Transferable Learning. Each module includes animations, narrative-driven content, scenario prompts, and interactive tasks. The platform ensures flexibility: it can be used in fully online, hybrid, or face-to-face settings. All necessary digital assets (readings, maps, videos, and quizzes) are embedded, so learners have a “one-stop” environment.
The core teaching narrative is anchored in this Engineering X case study. It documents the evolution of the Queensland Reconstruction Authority (QRA) from a short-term flood recovery body to a long-term resilience institution. This resource provides students with authentic socio-technical detail — including stakeholder conflicts, institutional learning, and systemic barriers — which they then interrogate using systems thinking frameworks.
This resource provides a suggested delivery schedule for facilitators. It maps when live sessions, asynchronous tasks, and group discussions should occur, ensuring students remain engaged over the course. It also indicates where key reflective points and assessments (both formative and summative) can be integrated.
5. Pre- and post-module assessment form: (Appendix C)
This tool evaluates students’ systems thinking learning outcomes. It includes:
Baseline survey: assesses initial understanding of systems thinking, approaches to complex problems, and confidence in collaboration.
Scenario-based survey: applies systems thinking questions to a specific context (e.g. extreme monsoon rains and flooding in the case of Sakura Cove – as per the group assignment in module 1).
Post-module survey: measures changes in understanding, confidence, and skills, while also capturing qualitative reflections on learning.
The form provides both quantitative data (Likert scales) and qualitative insights (open-ended reflections), enabling robust evaluation of teaching impact.
Assessment:
Formative: Pre- and post-module surveys assess changes in learners’ self-reported understanding of systems thinking (Appendix A). Facilitators may adapt reflective prompts and scenario-based activities as part of coursework.
Summative (optional): Students can integrate insights into ongoing design projects (e.g. climate resilience in urban redevelopment), with assessment based on problem analysis, stakeholder engagement, and solution development.
Narrative of the case:
Learners are introduced to the case via a fictional guide, “Bernice,” who frames the scenario and supports navigation through the material. Students work through three stages that progressively apply the Cynefin framework and other systems tools to understand how resilience emerges through evolving governance and engineering responses:
1. Context module:
Initial Mandate: Students explore how the QRA was first tasked with rapid technical recovery—fixing roads after flood damage.
Narrative Depth: They study the Queensland floods of 2010–11 not just as a physical shock, but as a systemic stress test on multiple layers: infrastructure, governance, and community systems.
2. Analysis & insights module:
Framework Application: Learners apply systems frameworks (e.g., Cynefin, stakeholder maps) to see how QRA’s remit expanded over time—from asset restoration to hazard anticipation and community resilience.
Knowledge Types: Students distinguish between explicit knowledge (e.g., rebuild standards, hydrology data) and tacit knowledge (e.g., local inter-agency trust, relational coordination).
Governance Layers: Activities explore how resilience depends on multi-level governance, local-state-federal coordination, and overcoming systemic barriers like funding cycles or short-lived institutional mandates.
3. Discussion & transfer learning module:
Reflective Debate: Students weigh whether engineering alone can deliver resilience, or whether social relationships and institutions are equally critical.
Barrier Identification: They debate typical constraints—political, funding, institutional—and propose ways systems thinking can mitigate them.
Transfer Lab: Learners apply the evolved QRA model to other scenarios—e.g., urban heat adaptation or wildfires—considering both technical measures and governance dynamics.
Interactive learning design:
The teaching activity integrates multiple interactive elements to immerse students in systems thinking:
Role-play simulations: Learners take on the role of Queensland Reconstruction Authority (QRA) decision-makers, negotiating trade-offs between immediate engineering fixes and long-term institutional resilience. This requires balancing technical priorities with building trust, relationships, and governance capacity.
Scenario challenges: Students are presented with governance disruptions (e.g. funding cuts, loss of stakeholder trust, leadership turnover). They must reframe solutions using systems approaches, moving from reactive technical patchworks towards adaptive, capacity-building strategies.
Interactive digital tools: The online platform provides hotspot maps for exploring interdependencies, drag-and-drop activities for categorising frameworks, explainer animations, and AI-driven chatbot negotiations with sceptical stakeholders. These exercises develop critical and applied problem-solving skills.
Collaborative reflection: Group discussions and peer-to-peer feedback allow learners to surface diverse perspectives, debate trade-offs, and integrate insights into ongoing project briefs.
Why this approach adds value:
Although rooted in social-technical interactions, the activity explicitly connects systems thinking to core engineering design competencies—problem framing, stakeholder analysis, and iterative solution development under uncertainty
Holistic understanding of resilience: Students experience resilience as more than just technical recovery. They engage with a dynamic system that includes knowledge creation, governance evolution, and social relationships.
Adaptive systems thinking in action: The evolving narrative demonstrates how system boundaries shift over time, and how sustainable outcomes require not only engineering but institutional and cultural change.
Direct relevance to real-world engineering: The case mirrors global infrastructure challenges where effective disaster response and resilience planning depend on the interplay between technical solutions, governance capacity, and community engagement.
Guided questions and activities:
Facilitators can use these prompts to stimulate inquiry and structured reflection:
Who are the key stakeholders in the QRA flood response, and where do their priorities align or conflict?
How do feedback loops and interdependencies influence resilience planning?
What trade-offs exist between rapid repair and long-term resilience?
How can systems frameworks such as the Cynefin model or stakeholder mapping guide decision-making under uncertainty?
In role-play: how would you convince a sceptical funder (AI chatbot) to invest in resilience measures?
How could lessons from flood mitigation be applied to other contexts such as wildfire or urban heat resilience?
Opportunities for extension:
In addition to the Queensland floods and Sakura Cove examples, educators may draw parallels with urban heat planning in London, wildfire adaptation in Australia, or storm resilience in the Netherlands. These comparative cases allow learners to generalise systems insights beyond one event or geography.
The activity is designed to be scalable and adaptable:
Broader case study base: Educators can expand beyond flood resilience to include wildfire, storm, or extreme heat events.
Integration with larger modules: The activity can be embedded into project-based learning modules (e.g. urban redevelopment, transport network resilience).
Advanced complexity: For higher-level learners, facilitators can introduce additional frameworks (e.g. agent-based modelling, system dynamics) to deepen analysis.
This flexibility allows educators to tailor the activity to their students’ level of expertise, institutional context, and disciplinary focus.
References:
Design Council. (2021). Beyond Net Zero: A systemic design approach. Design Council.
Godfrey, P., Crick, R. D., & Huang, S. (2014). Systems thinking, systems design and learning power in engineering education. International Journal of Engineering Education.
Monat, J., Gannon, T., & Amissah, M. (2022). The case for systems thinking in undergraduate engineering education. International Journal of Engineering Pedagogy, 12(3), 50–88.
Nachbagauer, A. (2021). Managing complexity in projects: Extending the Cynefin framework. Project Leadership and Society, 2, 100017.
Snowden, D. (2002). Complex acts of knowing: paradox and descriptive self‐awareness. Journal of knowledge management, 6(2), 100-111.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Licensing:This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License. It is based upon the author’s article “Enhancing Ethical Reasoning in Engineering Education through Student-Created Interactive Ethical Scenarios Using Generative AI,” 2025 IEEE Global Engineering Education Conference (EDUCON), London, United Kingdom, 2025, pp. 1-5, doi: 10.1109/EDUCON62633.2025.11016531.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, Life Cycle, Configuration Management, Requirements Definition, Verification, and Validation INCOSE Competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems). In addition, this resource addresses AHEP themes of Ethics and Communication.
Debug their simulation through playtesting, documenting issue → fix → retest cycles and demonstrating how changes improve coherence.
Explore trade-offs and justify decisions in ethics (e.g. consequences and equity) and complex systems (e.g. resilience vs cost vs emissions).
Evidence learning with transparent artefacts: initial prompt, changes via tracked changes or before/after snippets, tester feedback, and final prompt.
Reflect critically on validity, bias and the limitations of LLMs as simulators, including how to handle unsafe/poor choices by surfacing realistic consequences.
Communicate findings clearly to technical and nontechnical audiences.
Teachers have the opportunity to:
Use this as either a studio activity (3–5 sessions) or a compact assessment only task (1–2 sessions), with clear rubrics for each.
Standardise scope by offering a predefined scenario (e.g., Urban Heatwave Response, UK city), or permit student proposed topics.
Scale marking via artefact based evidence (prompt, change log, feedback, final prompt) rather than long reports.
Deliver with institutional Microsoft Copilot licences or any free web LLM; require students to disclose model and version used.
Adapt quickly to different disciplines by swapping the scenario pack (microgrids, water networks, medical device supply chains, etc.).
Overview:
This resource enables engineering students to create, run, and debug a text‑based, interactive simulation of a complex sociotechnical system using a Large Language Model (LLM). It is intentionally flexible and may be delivered as a multi‑session studio activity (including assessment) or used solely as a compact assessment.
Purpose and use:
In both modes, students design a robust text prompt, test it with a user, document changes, and submit auditable artefacts that evidence learning. The key activity is interrogating their own thinking on how complex systems should be modelled by making judgements as to how their game does and does not capture the system dynamics.
The submission is a text LLM prompt with tracked changes, which allows students to demonstrate system design and debugging, produce transparent process evidence, and scale to large cohorts with minimal infrastructure.
Delivery options at a glance:
Audience
Undergraduate Years 2–4 and taught MSc, any engineering discipline
Modes
Studio activity (3–5×2 h + independent study) or Assessment‑only (prompt‑only; 1–2×2 h + 4–6 h)
Teams
3–4 students (solo permitted for assessment‑only)
Assessment
Portfolio (studio) or prompt‑plus‑change‑log (assessment‑only)
Platforms
Institutional Copilot licences successful; encourage exploration of free tools (students record model/version)
Materials and software:
LLM access: institutional Microsoft Copilot licences (proven) or any reputable free web‑based tool. Students disclose the model and version.
Delivery modes:
Mode A — Studio activity (3–5 sessions)
Session 1: Frame the system — boundary, stakeholders, conflicting goals; sketch a Causal Loop Diagram (CLD) with at least two reinforcing and two balancing loops.
Session 2: Make it playable — define 4–8 state variables and KPIs; draft the prompt (based on Appendix A); specify commands, turn length and stop conditions; add debug controls (`trace`, `why`, `show variables`, `revert`).
Between sessions: Prototype v1 — run 10–15 turns; capture a transcript; log defects (e.g. inconsistent updates, missing delays, moralising responses).
Session 3: Play‑test and iterate — exchange prototypes across teams or test with an external user; record issue → fix → re‑test cycles with evidence (make sure edits are captured in tracked changes).
Session 4: Present and reflect — short demo (6–8 turns); explain how feedback/delays manifest; discuss surprises and limits.
Mode B — Assessment‑only (prompt‑only; 1–2 sessions)
Session 1: Brief and rapid scoping — select a scenario (student‑chosen or predefined); write a one‑paragraph boundary and stakeholders note; draft the initial prompt (based on Appendix A) with role choices, 4–6 state variables, simple commands, and a 12–15 turn cap.
Independent work: Debugging loop — run the prompt; identify faults; edit the prompt (make sure edits are captured in tracked changes); re‑run and capture short snippets demonstrating fixes; test with one peer and collect written feedback.
Session 2: Submission — students submit a single document with the initial prompt, change log (before/after snippets), tester feedback, the final prompt, and a short rationale of innovative choices.
In both modes, module leaders may supply a predefined scenario(s) to standardise scope and simplify marking. A ready‑to‑use example is provided in Appendix C.
Critical medical device supply chain — redundancy vs cost; equitable allocation.
Appendix A — Prompt template (simulation + debug‑ready):
Title: Complex Systems Simulator — [Scenario]
Purpose: Run a turn‑based interactive simulation of a complex sociotechnical system. Track named state variables, apply feedback and delays, and let the player’s decisions drive non‑linear outcomes.
Setup:
1) Offer three roles (distinct authority/constraints).
2) Introduce 3–5 NPCs with clear goals and plausible interventions.
3) Show a dashboard of [STATE_VARIABLES] each turn with short context.
State rules:
Track only these variables (with units/ranges): [list 5–8].
Maintain at least two feedback loops and one delay; keep hidden rule notes consistent across turns.
Each turn: recap; propose 3–5 options (plus free‑text); explain updates; show dashboard; request the following action.
Time step: 5 minutes to 1 week; end after 20–30 turns or on stop conditions.
Commands: status, talk [npc], inspect [asset], implement [policy], pilot [intervention], advance time, review log.
Debug commands (for testing): trace on/off (print update logic), why (state which loops/delays drove the change), show variables (print current state table), revert (roll back one turn), reseed (slight exogenous shock).
Realism and ethics: Allow all plausible actions and report consequences neutrally. If unsafe in the real world, refuse, propose safer alternatives, and continue with plausible systemic effects.
LLM pitfalls to avoid: Do not invent new variables; ask clarifying questions rather than guessing; keep outputs concise; summarise trajectory every five turns.
Begin: Greet the player, state the scenario, ask for a role, and wait.
Appendix B — Debugging and play‑test checklist:
Functional coherence
Do state variables update consistently with declared logic?
Are reinforcing and balancing feedback identifiable in play?
Robustness
Does the simulation permit negative choices with realistic consequences?
Do trace/why explanations match outcomes?
Are stop conditions respected?
User experience and clarity
Are commands clear? Is turn pacing appropriate?
Are dashboards concise and informative?
Report
Provide three concrete defects with turn numbers, the prompt edits that fixed them, and evidence of the re‑run.
Appendix C — Predefined scenario (Urban Heatwave Response, UK city):
Boundary: One UK local authority area during the July–August heatwave period. Focus on public health, energy demand, and community resilience.
Roles: (1) Local Authority Resilience Lead; (2) NHS Trust Capacity Manager; (3) Distribution Network Operator (DNO) Duty Engineer.
Stakeholders: Residents (with a focus on vulnerable groups), care homes, schools, SMEs, DNO, local NHS Trust, emergency services, voluntary/community groups, Met Office (for alerts), and local media.
State variables (examples): Heat‑health alert level (0–4); Emergency Department occupancy (%); Electricity demand/capacity (% of peak); Indoor temperature exceedance hours (hrs > 27 °C); Public trust (0–100); Budget (£); Equity index (0–100).
Events/shocks: Red heat alert; substation fault; procurement delay; misinformation spike on social media; transport disruption; community centre cooling failure.
KPIs and stop conditions: Heat‑related admissions; unserved energy; cost variance; equity gap across wards. Stop if alert level 4 persists >3 days, budget overspends >10%, or trust <25.
Notes for assessors: Using a standard, predefined scenario simplifies marking and ensures comparable complexity across teams, while still allowing for diverse strategies and outcomes.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Who is this article for?: This article should be read by educators at all levels of higher education looking to embed and integrate complex systems topics into curriculum, module, and / or programme design.
Premise:
Teaching and learning engineering carries with it a double layer of complexity. On the one hand, this complexity is connected to the growing interdisciplinary nature of engineering itself. On the other hand, the complexity is connected to the growing diversity of engineering students that are often present in one project team. This multifaceted complexity requires a re-envisioned understanding of the role and purpose of the engineering educator.
With the growing trend of a global classroom reality, we often find that learners in the classroom are representing different cultures, which in turn are rooted in them unconsciously carrying historical and socio-cultural baggage relating to these cultures. Thus, it becomes crucial to unpack the challenge and potential that such a diverse collective intelligence can offer to an engineering learning experience.
As our understanding of the engineering discipline gets more rooted and interconnected with the precarious reality that our world is witnessing today, it becomes essential that the engineering education community would take up a proactive role in actively contributing to the formation of engineering citizenship. In other words, every engineering student should be educated as a citizen that has mastered the engineering cross-cutting fields in such a way that they are free to create and solve problems of the present and the future.
With this in mind, it becomes very clear that the one-size-fits all model of a single discipline engineering classroom can no longer sustain itself. It does not factor in the richness that a diverse student body can offer, and it dilutes the value and potential of an engineering learner to think clearly or solve problems. It is therefore imperative that engineering educators grasp the complex reality of an integrated engineering discipline and address it in a way that fosters scaffolding of diverse knowledge. Some students might specialise in one core technical discipline. Yet, future projections for most students showcase the need to have a wide level of exposure to broader competency development. Students need to learn to understand the field of engineering at large and to develop system thinking skills that enable them to exist, challenge and have an impact on the system that they are a part of.
How to scaffold learning outcomes in a complex engineering curriculum:
The below table has been designed for embedding Complex Systems Learning Outcomes across an engineering curriculum. It maps against competencies and suggests scaffolding techniques across educational levels. It is also important to note, that efforts need to be made to align to the relevant AHEP requirements or other accreditation standards. Table 1 presents the different strands of the Complex Systems Engineering Curriculum, colour coded in line with the INCOSE Competency Framework outline (INCOSE, 2025). Table 2 presents a practical guide for educators to scaffold Complex Systems learning outcomes across a curriculum. The intention is for the scaffolding framework to compare the trade-offs between different elements of the competency group. For example, system modelling and analysis as an element from the core competency and planning from the management competency. The table suggests activities that would integrate different competencies together in a scaffolded approach.
Table 1 presents Competency Areas for Complex Systems. As mentioned, the skills range to include a wide variety of competencies, thereby enabling a solid and grounded systems thinking approach for students. As students approach their learning, they go through a series of development stages that gradually build up student level of expertise until they reach the stage of what the INCOSE competency framework refers to as a lead practitioner role. Building on the competencies of the complex system toolkit presented in Table 1, Table 2 presents a potential outline for a scaffolding framework that maps varying threads of the framework in a way that enables scaffolded activities at every developmental stage for learners. Depending on the learning context and educational level, educators can choose which level of attainment is appropriate to their curriculum.
As we are approaching the fuzzy front end to complexity in engineering pedagogy, as educators we need to be constantly toggling between devising frameworks, being informed by literature, contextualising ideas, validating these in our classrooms and repeating this cycle to continually fine-tune our complex teaching navigational complexity framework. The invitation is open for all educators who would like to connect as we continue to explore different ways of developing responsible engineers who leave a lasting and sustainable mark transforming their stationed realities.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, Systems Modelling and Analysis, Ethics and Professionalism, Technical Leadership and Critical Thinking INCOSE Competencies.
AHEP4 mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems). In addition, this resource addressesAHEP themes of Design, Ethics and Communication.
Educational level: Intermediate; Advanced.
Learning and teaching notes:
The case is built around 3 × 90-minute sessions and independent report writing. A suggested breakdown of the activities can be seen below.
Learners have the opportunity to:
Explore how technical, human, and organisational factors interact in complex socio-technical systems.
Apply Fault Tree Analysis (FTA) to diagnose ambiguous real-world engineering failures.
Practice making judgements under uncertainty with incomplete and conflicting data.
Analyse competing stakeholder perspectives and the ethical trade-offs in engineering decision-making.
Develop professional communication skills by producing expert reports and presenting findings to a stakeholder panel.
Reflect on their own reasoning, assumptions, and handling of complexity.
Teachers have the opportunity to:
Use an authentic, narrative-driven case to introduce systems thinking and failure analysis.
Facilitate active learning through group FTA construction and peer review.
Engage students in interdisciplinary learning that links materials science, engineering practice, regulation, and ethics.
Adapt the complexity of the case (technical vs organisational) depending on learners’ level and course focus.
Provide formative and summative assessment using expert reports, presentations, and reflective writing.
Encourage metacognitive development by prompting students to examine uncertainty and assumptions in engineering practice.
20 min: Introduce case scenario and system context; 30 min: Group discussion on initial impressions, key stakeholders, and potential causes; 40 min: Begin Fault Tree Analysis (FTA) construction using initial evidence.
2
Investigation and analysis
30 min: Continue FTA construction and data evaluation; 30 min: Peer review of other groups’ fault trees; 30 min: Consolidate findings and prepare draft report outline.
3
Reporting and reflection
30 min: Present findings to a simulated stakeholder panel; 30 min: Discuss feedback and defend conclusions; 30 min: Individual reflection on complexity, uncertainty, and assumptions.
Summary of the system or context:
Rail transport systems consist of thousands of interdependent components, including rails, fasteners, sleepers, signalling systems, and maintenance processes. Failures in a single component can cascade, affecting:
Safety: Malfunctions may cause derailments or delays.
Economics: Service interruptions lead to financial losses and reputational damage.
Public trust: Media scrutiny increases scrutiny of operational practices.
On a cold January morning, a commuter train was halted after inspectors discovered a fractured rail joint component. Services were disrupted for several hours, stranding thousands of passengers. The media quickly picked up the story, raising questions about safety and reliability.
The rail operator urgently commissioned an engineering consultancy (the students) to investigate the failure. Their findings will inform both the safety authority’s decision on whether the line can reopen and the legal proceedings to determine liability.
The dilemma:
The operator demands a rapid report to resume services.
The manufacturer insists the component was produced to specification and blames poor maintenance.
The regulator requires an unbiased, defensible technical opinion before approving operations.
The public expects transparency and reassurance about safety.
As consultants, students face incomplete evidence: some lab tests are missing, inspection logs are inconsistent, and eyewitness accounts conflict. They must use Fault Tree Analysis (FTA) to map possible causes, evaluate data, and produce an expert opinion report — knowing that their conclusions could influence legal outcomes and public safety decisions.
Groups: 3–5 students per group; 3-4 groups can run in parallel.
Materials required: case narrative handouts, sample inspection log, example FTA, whiteboards/flipcharts, sticky notes for FTA mapping.
Activity flow:
1. Introduce case and assign roles.
2. Construct initial fault trees using evidence.
3. Peer-review across groups.
4. Draft expert report and present to simulated stakeholder panel.
5. Individual reflection on complexity and uncertainty.
Why use Fault Tree Analysis (FTA):
FTA is a structured approach to trace a failure from an observed event back to potential causes, including technical, human, and organisational factors.
FTA is particularly suitable for this case because it allows students to structure complex, uncertain information in a logical and transparent way. It helps them trace the chain of causes behind the rail component failure, linking material, human, and organisational factors into one coherent framework. By visualising how small events combine into system-level failures, FTA encourages learners to think critically about interdependencies, data gaps, and assumptions. It also mirrors real-world engineering investigations, where professionals must justify conclusions under uncertainty and demonstrate clear reasoning to stakeholders such as regulators or courts.
Visualises cause-effect relationships, interdependencies, and failure paths.
Encourages discussion of assumptions and uncertainties.
Questions and activities:
Discussion prompts:
Prompt
Expected insight / reflection
What technical, human, and organisational factors might have contributed to this failure?
Students identify multiple interacting factors, illustrating interdependencies and emergent risks.
How does Fault Tree Analysis help structure uncertainty in this investigation?
Learners recognise FTA’s role in visualising cause-effect pathways and clarifying assumptions.
Which assumptions are you forced to make, and how might they affect your conclusions?
Students reflect on data gaps, biased observations, and ethical implications of assumptions.
How do different stakeholders’ interests shape urgency and framing of your analysis?
Learners understand trade-offs, pressures from conflicting priorities, and the precautionary principle.
What are the risks of issuing a preliminary report under time pressure?
Students explore implications for safety, liability, professional integrity, and public trust.
Classroomactivities:
Activity
Focus
What “good practice” looks like
Facilitator notes / tips
1. FTA construction
Collaborative problem analysis
Teams discuss evidence openly, question assumptions, and co-create a logical tree linking technical, human, and organisational causes.
Encourage each group to identify at least one “human/organisational” branch and to label any data gaps explicitly.
2. Peer review
Critical reflection and systems perspective
Groups provide constructive critique, highlighting hidden assumptions, missing branches, or unclear logic. Dialogue stays professional and evidence-based.
Provide coloured sticky notes or digital comments to record feedback; model how to frame critique as questions (“Have you considered…?”).
3. Report writing (in-class drafting)
Synthesis and professional communication
Drafts show a clear, defensible reasoning chain from evidence to conclusion. Teams justify assumptions and note uncertainties.
Remind students to separate “facts” from “interpretations.” Encourage use of structured headings (Findings – Analysis – Conclusions).
4. Simulation role-Play
Perspective-taking and communication under pressure
Presentations are concise (≤5 min), factual, and adapted to stakeholder roles. Learners respond respectfully and clearly to challenging questions.
Provide role cards for the panel (operator, regulator, manufacturer, public). Rotate students if possible.
5. Reflection
Metacognition and learning from uncertainty
Students identify what surprised them, what they found ambiguous, and how their view of engineering judgment evolved.
Offer prompts like “What would you do differently next time?” or “Where did your reasoning feel uncertain?”
Further challenge:
Instructors may choose to introduce a second “reveal” phase: a new metallurgical test result or a whistle-blower statement emerges halfway through the case. Students must revise their fault tree and defend whether and how their conclusions change. This highlights the evolving nature of complex systems investigations.
Assessment opportunities:
Fault Tree Diagram (30%) – accuracy, depth, clarity.
Presentation and defence (20%) – clarity, stakeholder awareness, handling questions.
Reflective summary (20%) – insight into uncertainty, assumptions, systems thinking.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Who is this article for?: This article should be read by educators at all levels in higher education who are seeking an overall perspective on teaching approaches for integrating complex systems in engineering education.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness.A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking, Systems Modelling and Analysis, and Critical Thinking INCOSE competencies.
AHEP mapping:This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems), and Integrated / Systems Approach (essential to the solution of broadly-defined problems). Additionally, this resource addresses the Problem Analysis theme.
Downloads: A PDF of this resource will be available soon.
Learning and teaching resources:
Glossary: This article refers to many concepts and terms which are more fully described and explained in this companion resource.
From smart cities and power grids to global supply chains, complex systems undeniably form the backbone of modern engineering challenges, integrating diverse technical and human domains to deliver resilient solutions that are capable of addressing emerging global demands. Traditional engineering approaches are limited in their ability to address increasingly complex and nonlinear problems, as they often fail to consider systems holistically. Complex systems exhibit dynamic behaviours and patterns that emerge from interactions within the whole, offering insights that go beyond what can be deduced from individual components (Martin, 2025).
However, recognising complexity alone is insufficient. To engage meaningfully with such systems, engineers and educators require systematic methods and analytical tools that make the structure, behaviour, and evolution of complex systems more transparent and tractable. Methods such as system dynamics, network analysis, agent-based modelling and causal loop mapping enable the identification of affected points, feedback mechanisms and unintended consequences providing a structured way to explore “what if” scenarios and support informed decision making. Without these tools, understanding remains largely intuitive and fragmented, limiting the capacity to model interactions, predict emergent behaviours or design resilient interventions.
There are many different ways to model complex systems, each suited to exploring particular types of interactions, timeframes, or behaviours. The following sections outline several commonly used tools and illustrate the contexts in which they can be effectively applied within engineering education. This guidance therefore focuses on the practical application and pedagogical integration of key complex systems methods and tools, with the aim of equipping engineering educators to embed systems thinking effectively in their teaching and practice.
Systems thinking and mapping tools:
Systems thinking provides a holistic perspective for students to explore the interdependencies, feedback loops, and emergent behaviours that characterise complex engineering challenges. A range of mapping and modelling tools can be used to visualise and analyse system structures and behaviours. These tools can be broadly categorised into three categories: qualitative mapping tools (such as rich pictures and influence diagrams) that support shared understanding and problem framing; causal modelling tools (such as causal loop diagrams) that reveal feedback structures and dynamic behaviour; and quantitative simulation tools(such as system dynamics models) that enable experimentation and testing of hypotheses.
Rich pictures, influence diagrams and causal loop diagrams are adaptable for both conceptual exploration and analytical modelling in engineering education. Each offers distinct advantages and limitations. Rich pictures are highly flexible, enabling diverse stakeholders to collaboratively capture multiple perspectives of a system. Their visual and narrative style promotes inclusivity and creativity but can lack analytical precision and consistency between users. Influence diagrams provide a more structured representation by showing directional relationships between variables, supporting clearer causal reasoning and decision making. However, they do not capture feedback or temporal dynamics, which limits their use in modelling evolving systems. Causal loop diagrams offer an advantage as they explicitly map, reinforcing and balancing feedback loops, giving powerful insights into system behaviour over time. However, these can become complex and difficult to interpret without adequate guidance and their qualitative nature may oversimplify quantitative relationships. When used in sequence, these tools can scaffold students’ systems thinking skills from exploratory mapping (rich pictures), through structural reasoning (influence diagrams), to dynamic analysis (causal loop diagrams). Embedding this progression in engineering education not only enhances students’ critical and reflective capabilities but also enables them to identify leverage points, anticipate unintended consequences and design resilient solutions that respond effectively to the complexity of real-world complex systems.
Figure 1 presents a product causal loop diagram illustrating how product quality, sales, investment and profitability interact through reinforcing and balancing feedback loops. Two reinforcing loops (R1 and R2) show how profitability and product quality can drive self-sustaining growth: higher profits enable reinvestment in sales, while improved quality enhances customer satisfaction and market demand, both improving overall performance. In contrast, two balancing loops (B1 and B2) act as stabilising forces. When rapid sales growth strains production capacity, quality declines, prompting corrective investment to restore standards (B1). Meanwhile, as quality improves, it eventually reaches a maximum threshold where further gains lead to diminishing returns (B2), reflecting real-world technological and resource limits. Together, these loops demonstrate the dynamic interaction between growth and constraint in complex systems. The model highlights how feedback processes shape organisational performance and underscore the value of systems thinking for anticipating unintended consequences and supporting sustainable decision making in educational contexts where understanding system dynamics enhances learning and design practice.
System dynamics (SD) models simulate system behaviour over time by representing key elements such as stocks, flows, feedback loops, and time delays. This approach is particularly useful for understanding long-term patterns and testing interventions in complex contexts, such as modelling energy demand, tracking carbon emissions, or optimising supply chain dynamics. By using accessible tools like Stella, Vensim, or Insight Maker, educators can create interactive learning experiences that allow students to experiment with ‘what-if’ scenarios, deepen their understanding of dynamic behaviours, and develop the skills needed to make informed, data-driven decisions. Figure 2 illustrates a dynamic stock-and-flow diagram of a model for new product adoption. The diagram demonstrates how stock and flow structures can capture accumulations and delays within a system, providing insights into how adoption rates evolve over time in response to feedback processes.
Figure 2. Dynamic stock and flow diagram of model New product adoption(taken from Wikipedia: model from article by John Sterman 2001 - True Software)
Agent-based modelling:
Agent-Based Modelling (ABM) analyses complex systems by simulating the actions and interactions of many individual “agents” each following simple behavioural rules. Agents can represent people, vehicles, organisations or even machines depending on the context and their collective behaviour gives rise to larger system patterns that are often unexpected or counterintuitive. For example, in a traffic flow model, each car (agent) follows basic rules for acceleration, braking and lane changing. While these rules are simple in isolation, their combined effects can lead to emergent phenomena such as traffic jams or wave-like congestion patterns, behaviours not explicitly programmed into the system. Similarly, in a disease transmission model, each agent might represent a person whose movement and interactions influence infection spread across a population, providing valuable insight into intervention strategies.
ABM is particularly useful in systems where differences among agents and local interactions matter. Whereas System Dynamics (SD) captures aggregate feedback through mathematical relationships, ABM reveals the distributional and spatial dimensions of system behaviour by modelling individual actions and decisions. Educators may choose ABM to help students see how microscale decisions lead to macroscale outcomes, reinforcing the concept that system-level order often emerges from local and uncoordinated interactions. Open-source platforms such as NetLogo provide accessible environments for teaching these principles, offering pre-built models that allow students to experiment with agent rules and parameters. Through such interactive exploration, engineering students can observe how small behavioural changes can cascade into large-scale effects deepening their understanding of emergence, adaptability and complexity in real-world complex systems. Figure 3 presents a schematic of an agent-based model, illustrating how interactions among individual agents within an artificial environment can lead to emergent system-wide patterns.
Network analysis looks at how the pattern of connections within a system affects how it behaves, performs, and recovers from disruption. Instead of focusing on individual parts, this approach studies the relationships between elements whether they are people, machines, or data points and how these connections shape the overall outcome of the system. In network science, two important ideas help describe how a network is organised: degree distribution and clustering coefficients. Degree distribution shows how many connections (or “links”) each element, known as a node, has. If most nodes have a similar number of links, the network tends to behave in a steady and predictable way. However, if a few nodes have many more connections such as major airports in a flight network, the system can operate very efficiently but may also become more vulnerable if one of those key nodes fails. Clustering coefficients measure how connected a node’s neighbours are to each other. A high clustering coefficient means that a node’s connections are also well connected, forming strong local groups. This structure can improve communication and resilience within the network, though it may also limit flexibility or slow the spread of new information.
By analysing these features, students learn that the way parts of a system are connected is just as important as the parts themselves. Real-world complex systems examples include power grids, transport networks, and organisational systems, where understanding connectivity helps engineers identify weaknesses and design for greater robustness. Tools such as Gephi and NetworkX make it possible to visualise and measure these network properties, helping turn complex data into clear, interpretable diagrams. Figure 4 shows the structure and properties of a technological network, illustrating how node connectivity and clustering together influence the system’s overall resilience.
Understanding and managing complexity is now an essential skill for modern engineers. By gradually introducing students to different systems thinking tools from qualitative mapping to dynamic simulation and network analysis, educators can help them build a deep and transferrable understanding of how complex systems behave. Each tool offers a different perspective: mapping tools encourage exploration and shared understanding, dynamic models reveal feedback and time-based behaviour, and network analysis exposes structural patterns and resilience. Taken together, these approaches form a developmental pathway that strengthens students’ ability to think critically, reason systematically, and make informed design and management decisions. Embedding this progression within engineering education cultivates curiosity, adaptability, and a mindset equipped to tackle the interconnected social, environmental and technological challenges of the future. In doing so, educators prepare graduates not just to work with complex systems, but to improve and transform them.
References:
Avison, D. E., Golder, P. A. and Shah, H. U. (1992) ‘Towards an SSM toolkit: rich picture diagramming’, European Journal of Information Systems, 1(6), pp. 397–408. doi.org/10.1057/ejis.1992.17
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Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.
Who is this article for?: Thisarticle should be read by educators at all levels in higher education who are seeking an overall perspective on teaching approaches for integrating complex systems in engineering education.
Related INCOSE Competencies: Toolkit resources are designed to be applicable to any engineering discipline, but educators might find it useful to understand their alignment to competencies outlined by the International Council on Systems Engineering (INCOSE). The INCOSE Competency Framework provides a set of 37 competencies for Systems Engineering within a tailorable framework that provides guidance for practitioners and stakeholders to identify knowledge, skills, abilities and behaviours crucial to Systems Engineering effectiveness. A free spreadsheet version of the framework can be downloaded.
This resource relates to the Systems Thinking andCritical Thinking INCOSE competencies.
AHEP mapping: This resource addresses several of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): Analytical Tools and Techniques (critical to the ability to model and solve problems),and Integrated / Systems Approach (essential to the solution of broadly-defined problems).
Premise:
We live in a complex world. Complexity is a key challenge, captured in leadership terms by the VUCA framework: volatile, uncertain, complex and ambiguous (Lanucha 2024). Engineers have the privilege of creating products and processes for humans to use in this landscape. Each of these likely has numerous parts which interact, as well as interacting with the environment, people, and needing to meet a host of safety, quality, sustainability, ethics, and financial obligations. Traditionally, engineers analyse problems by breaking them down into simple parts. This helps understanding and makes calculations feasible, but it’s easy to lose understanding of the whole system. Any change can easily create a problem elsewhere. From a technical viewpoint, engineers need to understand this interconnectedness in order for their creations to work. In a wider sense, ‘systems thinking’ is a skill central to engineering quality and management techniques, which seek to rationalise the complexity of entire organisations and their ever-changing market pressures.
The case for understanding systems:
Systems is perhaps one of the most misunderstood words in engineering. It is often found combined with mathematical modelling or control – topics often perceived as challenging – and is used in other fields like Computer Science, where tools and models are different. In all cases, the idea revolves around a group of interacting or interrelated elements which form a unified whole. Those elements can be physical or information, hardware or software, or any combination of mechanical, electrical, and other engineering domains. Thinking in terms of systems can therefore be thought of as a holistic approach.
The Engineering Council UK’s AHEP criteria include a systems approach: C/M6 – “Apply an integrated or systems approach to the solution of complex problems.” Several other AHEP criteria also reference complexity and complex problems, which they define as having “no obvious solution and may involve wide-ranging or conflicting technical issues and/or user needs that can be addressed through creativity and the resourceful application of engineering science. The Systems Thinking Alliance (2025) gives a broader definition of complexity as referring to “the condition of systems, objects, phenomena, or concepts that are challenging to understand, explain, or manage due to their intricate and interconnected nature. It involves multiple elements or factors that interact in unpredictable ways, often requiring significant information, time, or coordinated efforts to address.” For these, there is no ‘one-size-fits-all solution’ (Ellis 2025). This is the reality that engineers need to manage by understanding the potential effects on all parts of the system.
In order to analyse, engineers dissect complexity into manageable components, and educators teach these simple components before moving onto more complex systems. For example, students initially learn basic electrical components, simple beams, rigid bodies, etc. before bringing these together in case studies, and then moving onto topics like mechatronic systems. Historically, engineers specialised on graduation, perhaps becoming a stress engineer or fluid dynamicist in dedicated offices and functional teams. A design decision by one team could have unintended consequences for another, as well as additional uncertainty. The advent of cross-functional project and ‘matrix’ organisations mitigated against this, and companies have moved towards attribute teams which can consider the balance of behaviour. Even so, some uncertainty remains in the form of assumptions in calculations, changes in material properties with temperature or stress, or small variations in composition and manufacturing tolerances, which can all accumulate. Any parts which are bought ‘off-the-shelf’ or made by other companies under license must be carefully specified. Relationships can be nonlinear – or even chaotic – and contain feedback loops which can amplify changes (Kastens et al 2009). This all increases the risk of a product’s comfort, performance, and safety being impacted in ways that weren’t anticipated. Any problem that doesn’t come to light until the testing phase – late in the design process – represents costly redesigns and delays. In the unlikely event that a problem isn’t captured during testing either, the outcome could be disastrous.
Systems engineers will bring the product together and establish these complex behaviours through models and testing. Identifying potential problems early in the design phase can save significant money and facilitate better designs. This can be challenging, especially for systems using novel materials or operating in extreme environments, which aren’t accurately captured by standard calculations. Models may be linearised, neglect external forcing, or be derived for an assumed air density or ambient temperature which may not be valid. In recent decades, the engineering industry has moved towards model-based design and virtual prototyping, facilitated by advances in computer tools. These are increasingly sophisticated, but models still need to be built by engineers with an appreciation of complexity and the mechanisms by which a problem could arise. As humans develop new materials and technologies, and explore the limits of what is possible, engineering techniques and calculations need constant revision, and software tools are frequently updated to facilitate this.
That holistic view of problems has benefits outside of designing engineering artefacts. The manufacturing process is itself a complex system with potentially long supply chains. As is the organisation, which is comprised of numerous people operating in a landscape of financial pressures, employment law, politics and culture. Quality guru William Deming’s 14 Points for Management (Deming 2018) can be viewed as a systems approach to handling this complexity, by breaking down barriers between departments and instigating continuous improvement. Once a product is produced, it exists in a wider world and continues to interact with it. From a sustainability viewpoint, this can be the user and surrounding community, the environmental impact over a product’s lifecycle, and the financial markets which dictate whether a product is viable. It can also be the social, political, and legal landscapes: these can place direct constraints in the forms of laws governing safety and emissions (such as the UK’s legally binding target of net zero by 2050), or through embargos, tariffs, and subsidies. Each country has its own regulations, which can necessitate multiple variations of a product: a good example is cars, which need to be produced in both left- and right-hand drive, satisfy varying safety and emissions regulations, and cater for differing personal and cultural preferences for size, noise, usage and driving styles. Even when not legislated, a company might choose to support fair trade, lead the way in sustainable practices, or refuse to do business with suppliers or regimes they find objectionable – potentially making this a key part of their brand.
An engineer’s ability to appreciate and understand the wider social and business landscape is a reason why finance and management consultancy companies can often be seen recruiting engineers at student careers fairs. The Sainsbury Management Fellowship (SMF) scheme notably develops UK engineers as industry leaders, and fellows have made a major contribution to the UK’s economic prosperity (RAEng 2025).
Conclusions:
Complex systems are the “real world” that engineers attempt to understand and design for. They are complicated, interconnected, changing, and uncertain. The well-known part of engineering is analysis: breaking systems into understandable parts. There needs to be a parallel operation where those parts are assembled or integrated into a whole, and that whole interacts with everything around it. This is where unforeseen problems can occur. Systems models and a holistic systems thinking approach can mitigate this risk. A systems approach and ability to manage complexity is a key skill for engineers, and positions them well for other fields like management.
Kastens, K., Manduca, C., Cervato, C., & Frodeman, R., Goodwin, C., Liben, L., Mogk, D., Spangler, T., Stillings, N., Titus, S. (2009). How Geoscientists Think and Learn. Eos, Transactions American Geophysical Union. 90. 10.1029/2009EO310001.
Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.