Purpose This paper aims to present a process to generate physics-based trade-off curves (ToCs) to facilitate lean product development processes by enabling two key activities of set-based concurrent engineering (SBCE) process model that are comparing alternative design solutions and narrowing down the design set. The developed process of generating physics-based ToCs has been demonstrated via an industrial case study which is a research project. Design/methodology/approach The adapted research approach for this paper consists of three phases: a review of the related literature, developing the process of generating physics-based ToCs in the concept of lean product development, implementing the developed process in an industrial case study for validation through the SBCE process model. Findings Findings of this application showed that physics-based ToC is an effective tool to enable SBCE activities, as well as to save time and provide the required knowledge environment for the designers to support their decision-making. Practical implications Authors expect that this paper will guide companies, which are implementing SBCE processes throughout their lean product development journey. Physics-based ToCs will facilitate accurate decision-making in comparing and narrowing down the design-set through the provision of the right knowledge environment. Originality/value SBCE is a useful approach to develop a new product. It is essential to provide the right knowledge environment in a quick and visual manner which has been addressed by demonstrating physics knowledge in ToCs. Therefore, a systematic process has been developed and presented in this paper. The research found that physics-based ToCs could help to identify different physics characteristics of the product in the form of design parameters and visualise in a single graph for all stakeholders to understand without a need for an extensive engineering background and for designers to make a decision faster.

Set-based concurrent engineering (SBCE), also known as set-based design, is a state-of-the-art approach to the new product development process. SBCE, simply, provides an environment where designers explore a wide range of alternative solutions in the early stages of product development. After gaining knowledge, solutions are narrowed down until the optimal solution is ensured. Such an environment saves considerable amount of cost and time while reaching innovation and high quality in the products. However, industrial practitioners seek a clear and systematic application throughout an SBCE process. This paper demonstrates a well-structured SBCE process model and its step-by-step application on a product called “electronic card reader”. Real data is used in the industrial case study. Results showed the benefits of applying SBCE in both the product, and the process of new product development.