Integrating Digital Threads Across Engineering Organizations: A Q-methodology Analysis of Challenges with a Novel Factor Selection Approach

Abstract

This research investigates the integration of digital tools across design, manufacturing, and quality management functions through a cross-industry analysis informed by Q-methodology. Despite considerable investments in digital transformation, many manufacturing organizations face persistent gaps between design intent and production execution, exacerbated by fragmented digital threads, limited adoption of Model-Based Definition, and the continued reliance on manual, error-prone workflows. Through qualitative interviews and quantitative Q-sort analyses conducted among participants across diverse industries, this study identifies key patterns of pain points and solutions perceived differently by stakeholder groups. It reveals insights into how variations in industry characteristics influence digital maturity, particularly regarding the adoption and integration of Product Lifecycle Management, Model-Based Enterprise, and Design for Manufacturability practices. Findings underscore the critical role of enhancing digital thread connectivity, ensuring early integration of manufacturability feedback, embedding automated cost analytics, and facilitating supplier readiness for full MBD adoption. Furthermore, the research highlights the necessity of strategic organizational change management alongside technological advancements. This work provides a nuanced understanding of organizational perceptions and identifies tangible pathways toward a cohesive, software-driven approach for bridging gaps among engineering functions, thereby informing future strategies for manufacturers and software vendors alike.