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Companies are challenged to achieve maximised benefits in time, money and novelty when introducing new products or technologies into their existing manufacturing systems. This paper set the focus on the introduction of new materials into existing products and if the adverse effects on manufacturing will outweigh the benefits. An automotive case was studied where discrete event simulation was used as tool to evaluate process consequences when introducing new material and process technologies into the production system. The question concerned if discrete event simulation can verify production system capabilities even in early conceptual design stages. The case analysis is concluded by three challenge areas concerning early stages of production system design. The difficulties of evaluating operational key performance indicators early in design processes become evident and needed future research efforts within the area are pointed out. © 2016 The Authors.