The Growth of Complexity in New Systems Engineering

Product Development Engineering

The Growth of Complexity in New Systems Engineering

Applied Philosophy

Introduction: Growth of Complexity

Essentially, the Growth of Complexity is never static. Generally, once it enters a system, it tends to expand, often in ways that are natural and invisible at first. Naturally, engineers may add a single feature or change one requirement, but behind the scenes, dozens of new interactions begin to take shape. Over time, what started as a small addition can reshape the entire system.

Growth is not the same as size. When a system becomes larger, it gains more parts. When a system becomes more complex, it gains more relationships among those parts. Two components may connect in one way. Ten components may connect in dozens of ways. The number of links grows much faster than the number of elements. This is why complexity feels overwhelming—interactions multiply more quickly than we expect.

Philosophers describe this as emergence. The whole develops behaviors that the parts alone cannot explain. Birds flying in formation create patterns that no single bird controls. Financial markets react in ways that no single participant intends. In the same way, engineering systems gain new behaviors, some intended and some unexpected, as functions accumulate.

For automotive engineers, this growth is not optional. Modern vehicles demand advanced driver assistance, electrification, and connectivity. Each of these technologies requires new functions that link to existing systems. As a result, complexity expands with every model year and vehicle design.

Natural Accumulation

Essentially, the Growth of Complexity of system intricacy begins with something simple: adding new parts or functions. Furthermore, every addition seems small, but the effect is rarely contained to just that element. Moreover, each part connects with others, and each connection introduces more interactions. Growth is not linear; it accelerates as elements multiply.

This natural pattern appears across every engineering discipline. In software, one new function often requires multiple supporting libraries. In electronics, a single new sensor may need additional wiring, signal conditioning, and communication protocols. Each supporting element then links back into the larger architecture.

In vehicles, growth appears in both expected and surprising places. Adding a driver monitoring system does more than place a camera in the cabin. It requires data storage, links to driver displays, algorithms for detection, and cybersecurity measures to prevent misuse. Each of these layers introduces its own connections to existing systems. What began as one feature now ripples through the architecture.

A similar pattern occurs in infotainment. Adding a single app or feature—say, voice recognition—seems like a small improvement. But it requires microphone hardware, signal processing, natural language models, user interface updates, and connections to navigation or media systems. Each of these creates dozens of new test cases, validation steps, and potential points of failure.

This natural accumulation explains why programs often underestimate cost and effort. Each new requirement, sensor, or line of code is never isolated. Instead, it reaches outward, touching multiple parts of the system. The more we add, the harder it becomes to predict where all the interactions will lead.

Statistics: Growth of Complexity

The Growth of Complexity can be described in measurable terms, not just concepts. Consider the simplest case: two parts joined together. Each part carries its own requirements, and their connection adds new requirements at the interface. Add a third part, and the number of interfaces increases again. The count of requirements grows faster than the count of parts, because every new element creates more than itself—it creates relationships.

This effect can be expressed statistically. With nnn parts, there are nnn sets of component requirements plus a growing number of interface requirements. In sparse designs, the interface count rises in proportion to the number of parts. In dense designs, the count can approach n(n−1)2\tfrac{n(n-1)}{2}2n(n−1)​, meaning each new part adds multiple new links. Even with modest assumptions, the interface term quickly dominates the total. Verification and validation must follow this same growth pattern, since every requirement and every interface must be tested in some form.

Quality standards highlight the same challenge from another angle. In Design for Six Sigma (DFSS), the well-known benchmark is “six parts per million” allowed to be faulty. Yet when thousands of critical parts are combined into a single vehicle, that allowance compounds. At the vehicle level, the probability of at least one defect rises sharply. Achieving six-ppm quality at the vehicle level would require per-part quality measured in parts per billion, or effective detection and containment measures to catch faults before they reach the customer.

Continued

Consequently, without support from working models developed in parallel with hardware, the verification and validation burden would expand beyond manageable limits; simulation makes it possible to anticipate requirement growth one step ahead of physical design.

These statistics reveal the underlying truth: complexity grows faster than our intuition suggests. It multiplies through requirements, interfaces, and probabilities. Recognizing this measurable acceleration prepares us to understand why some elements act as multipliers, spreading complexity far beyond their immediate scope.

Interdependence and Hidden Multipliers

The growth of system depth is not evenly distributed. Some elements act as multipliers, creating far more connections than expected. These hidden multipliers explain why complexity often grows faster than anyone planned.

Software is the clearest example. Adding one new software module rarely affects just a single function. Instead, it can touch dozens of signals, algorithms, or user interfaces. A small change in the code that manages braking, for instance, may also affect stability control, driver assistance, and diagnostics. What looked like a simple update expands into a wide set of interactions.

Systems engineers often describe this using the idea of tight coupling vs. loose coupling. Tightly coupled systems share many dependencies: a change in one area quickly spreads to others. Loosely coupled systems isolate changes better, allowing teams to work with less risk of ripple effects. Growth accelerates most in tightly coupled architectures, where multipliers amplify every change.

Hidden multipliers also exist at the organizational level. A single requirement that cuts across multiple teams becomes a source of exponential work. Consider cybersecurity: one new regulation can force updates to infotainment, diagnostics, wireless communication, and even powertrain controllers. Each team depends on the same rule, so a change in interpretation or implementation forces rework everywhere at once.

These multipliers often remain invisible until late in the project. The extra interactions surface only when testing, integration, or validation begins. By then, the growth has already consumed resources. Recognizing potential multipliers early—whether a software dependency, a shared requirement, or a common resource—is essential.

Understanding interdependence helps engineers anticipate where system growth will accelerate. The lesson is clear: not every part adds equal weight. Some elements multiply the effort many times over. Identifying them is the first step toward managing growth before it overwhelms the program.

Automotive Examples: Growth of Complexity

Modern vehicles provide clear evidence of how system intricacy grows. Each new technology adds not only parts but also layers of interaction across existing systems. The effect is often exponential rather than linear.

Take ADAS features. Adding lane-keeping assistance requires more than a steering input sensor. It calls for cameras, radar, central processors, and algorithms that interpret driving conditions. These elements must then integrate with braking, stability control, and driver interfaces. What began as a single function grows into an entire network of interdependent subsystems.

Electrification shows another kind of growth. Designing a battery pack requires thermal management, charging protocols, safety monitoring, and high-voltage isolation. Each addition links to different teams—cooling hardware, software controls, charging infrastructure, and regulatory compliance. A new cell chemistry or thermal design cascades through the entire program.

Connectivity multiplies interactions further. A single over-the-air update pathway touches infotainment, cybersecurity, diagnostics, and backend server integration. A change in one layer often requires updates in others. Growth accelerates as regulatory requirements add further layers of approval and validation.

Continued

Generally, different manufacturers handle Growth of Complexity differently. Tesla, for example, manages growth through a centralized software stack. Moreover, its architecture remains tightly coupled, which allows fast feature integration but also concentrates risk when issues appear. Overall, traditional OEMs, by contrast, rely on distributed supplier networks. Their growth is spread across many teams, which can slow integration but provides resilience against single-point failures. Therefore, both strategies illustrate the same principle: growth is inevitable, but its path depends on how systems are structured.

These examples highlight that automotive systems rarely expand in isolation. A feature that seems small from the outside—an alert, a new charging mode, or a software update—creates waves of change throughout the architecture. This is why complexity in vehicles grows faster than the number of parts or lines of code would suggest. It is not just about adding elements; it is about the multiplication of their interactions.

Conclusion: Growth of Complexity

Growth is not a side effect of complexity—it is its defining property. Once present, system depth expands naturally as new parts, functions, and relationships accumulate. The pace of growth is shaped by hidden multipliers, such as software modules or shared requirements, that add far more connections than expected. In modern vehicles, this growth is visible everywhere: ADAS, electrification, and connectivity all introduce layers of interaction that spread across the entire architecture.

Philosophically, growth reflects the nature of living systems as well. Human societies, ecosystems, and markets all show the same pattern: once relationships form, they tend to expand. Complexity is therefore not an anomaly of engineering but part of how systems evolve.

For engineers, the challenge is not to stop growth. That would mean stopping progress itself. The real task is to recognize where growth occurs, anticipate the effort it will demand, and prepare systems to handle it. When engineers account for growth early, they avoid being surprised by the web of connections that appears later in validation or integration.

The next article in this series will take a closer look at the statistics behind growth. In Counting Complexity – Why Interfaces Grow Faster Than Parts, we will examine how adding elements creates a progression of requirements and interfaces, and why verification and validation burdens grow faster than intuition suggests.

References

References to Complexity in Systems Engineering Series:

  1. What Do We Mean by Complexity? 
  2. The Growth of Complexity <—You are here
  3. Counting Complexity – Why Interfaces Grow Faster Than Parts
  4. Propagation: How Complexity Spreads 
  5. Complexity Reduction: The Discipline of Simplification
  6. Optimization: Improving the Existing System
  7. Requirements: The First Line of Defense
  8. Measuring and Managing Complexity
  9. From ppm to ppb – The Statistical Reality of Vehicle Defects
  10. Complexity in Practice: Case Studies & Critiques
  11. Simulation and Virtual Models – Managing Complexity in Verification and Validation

Systems Engineering References

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