From Proof of Concept to Industrial Deployment: Application of Multi-Level FBS, TRIZ and Lean Six Sigma to Wave Energy Conversion

This study presents a structured, integrated methodology that combines Lean Six Sigma and TRIZ to support the transition of a wave energy converter from a laboratory proof-of-concept to an industrializable system. It addresses key techno-economic challenges, including high cost, limited efficiency, maintenance constraints, and scalability limitations, by systematically resolving underlying technical contradictions through the DMAIC framework. In the Define phase, industrial requirements were established, focusing on robustness, maintainability, and performance under irregular wave conditions. A laboratory-scale prototype based on a point absorber coupled to a linear generator was developed to validate the wave-to-wire conversion concept. The Measure phase quantified system performance, recording peak voltages up to 3.7 mV and demonstrating a correlation (R² = 0.75) between experimental and theoretical results. The analyze phase integrated performance data with Function-Behaviour-Structure analysis to identify root causes and key contradictions in system scaling. In the Improve phase, TRIZ tools were used to generate optimised design solutions, including coil redesign, hydrodynamic improvements, and a segmented generator architecture. Finally, the Control phase outlines a roadmap for a Generation 2 prototype under real sea conditions. Overall, the study contributes a systematic, need-driven framework that bridges the gap between conceptual validation and industrial deployment, while proposed design solutions require further experimental validation.