Reducing design complexity (DC) has become a widespread interest for new product development. As DC

increases, the cost, time and resources required for production also increase. Consequently, there is an essential need to accurately measure DC. Prior research has shown that there is a gap in the current literature related to

understanding and quantifying the DC of highly regulated products such as medical devices. While existing metrics focus on various aspects of DC, a more generalized metric has not yet been developed to integrate all of these aspects. Therefore, this paper presents the study of a hundred FDA-approved hip replacements for the analysis of DC in the context of medical devices. Product information and surgical techniques were gathered to analyze surgical steps, functions, components with its interactions and variations. Through correlation analysis, the relationships between these factors and pre-existing metrics were evaluated to develop three new metrics that combine uncorrelated variables. The new metrics will provide a more accurate measure for the DC of new products and therefore a better understanding of its impact in the cost, time and resources required for production.