This work investigates the issue of weight reduction in moderately complex systems by addressing how to cascade the requirements to the individual components. Though mass can be reduced using different techniques such as material substitution or structural optimization; a systematic method is necessary to provide novel alternate solutions that enable reduction of mass of the system while satisfying the requirements and tests governing them. Such a method has been developed by exploring different aspects of achieving weight reduction through change propagation in the parameters/elements governing the system. The systematic method to generate solutions for mass reduction presented in this work includes generation of solutions at an assembly level and component level of the system by eliminating non-functional requirements, merging functions, finding alternate working principles and their embodiment that satisfy the functionalities, requirements and tests imposed on that system. A case study is conducted on the BMW Z4 cooling system. A visualization tool and accompanying algorithms have been developed to facilitate change propagation and traceability.

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