The Value of Simulation Process & Data Management Data ...

The Value of Simulation Process & The Value of Simulation Process & Data Management Data Management –– Lessons from a Lessons from a

Decade of Production ExperienceDecade of Production ExperienceDecade of Production ExperienceDecade of Production Experience

• Mark Norris MSC.Software

AgendaAgenda

• Business and Operational Challenges• SPDM Capabilities to address these Challenges• Implementation Approaches & Achievements• Business Value & ROI

NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010

Business ChallengesBusiness Challenges

• Quote Customers Faster• Increase the accuracy of quotes for wins &

margin• Reduce Physical Prototype Costs• Reduce Physical Testing Costs


MD Simulation-Based Development is the Answer

• Reduce Physical Testing Costs• Reduce Development Costs• Accelerate Product Introduction• Achieve Market leading Product Performance• Introduce more Products• ……

The Simulation ChallengeThe Simulation ChallengeExpanding Capacity, Managing Process & DataExpanding Capacity, Managing Process & Data

� # of CAE Simulations� Complexity of Simulations� Data per Simulation

Nearshore/Offshore Development & Integration


Driving Demand for Analyst Productivity

Source: BMW

Challenges of Managing Simulation Data Challenges of Managing Simulation Data • Data Volume, Visibility and Traceability

– Terabytes of files per day, typically managed on file systems with limited access controls & traceability

– Processes are not formalised– Results are buried in files or documents – Collaboration & Supervision are by meeting– Reports & Audit trails are manual– Which result from which inputs by what process?


– Which result from which inputs by what process?– Which files can I delete?

• Staff spend up to 50% of their time searching for d ata

Globalization & Distribution of EngineeringGlobalization & Distribution of Engineering


• Distance magnifies Challenges– Collaboration & supervision of

simulation tasks is complicated by time-zones, languages, cultures

– Work in Progress is inaccessible– Only Meshing can be distributed

geographically or outsourced -because validation is easy

MultiMulti--Discipline magnifies the ChallengeDiscipline magnifies the Challenge

• Transfer and trace-ability of data sets between departments and disciplines are problematic

• Rework due to problems with transfer and traceability between disciplines has been identified as a key issue in Aerospace

• I want to be able to trace back through the entire process:


• I want to be able to trace back through the entire process:

SimulationCFD

ModelFile

RegimeOption

Vehicle CAD

Configfile

ResultsLoads

LoadState

SimulationMD Nastran

ModelFile

MaterialsComposite

Geometry CAD

ResultsStresses

LoadsInput

Stress

Aerodynamics

Partner Interaction magnifies the ChallengePartner Interaction magnifies the Challenge

• Key Issue here is transfer and traceability without full disclosure of Intellectual Property

• Partners must only be able to access necessary (interface) data, must not be able to access other partners’ data


partners’ data• Partners cannot risk disclosure of their proprietary

know-how• Typical solution is manual exchange of data files,

traceability and pedigree are defined in documents

Respondents were asked what categories of data should be managed within an SDM system

70%

80%

90%

100%Managed by the SDM system In scope for SDM but managed elsewhere


0%

10%

20%

30%

40%

50%

60%

70%

Final reports

Process data

Process execution

In work data

Catalog & reference

Test data Business data

Product data

Categories of data to be managed

Engineering Engineering OrganisationsOrganisations need:need:

A global secure platform to• manage data & process• enable collaboration, remote working, outsourcing

and process automation• ensure Traceability and Deliver Certainty


• ensure Traceability and Deliver Certainty

• SimManager has been delivering in production for a decade


SPDM SPDM CAPABILITIES CAPABILITIES

ManagingManaging Simulation ExecutionSimulation Execution

Modeling & Assembly

Load Case Setup Post-processKey Results

Create Reports

Job Submit

NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 201011/16/2010 12

SimManager Process Management


What were the Inputs? the Process Parameters, the O utputs? the Key Results? ….. Structure provides the Answer

Validated Material data

Information Structures deliver ValueInformation Structures deliver Value

Validated

Automated model assembly

Work In Progress Visibility

Validated Process Templates

Process Execution data

Results Traceability

Key Results Visibility

Automated Reporting of

Post-Processing Automation


Validated meshes

Reporting of Machine-Readable Structures

Immediate Audit Trail for Regulatory Compliance

Secure Structure access enables remote work & outsourcing

WIP visibility enables 24/7 Global Collaboration

Structure maintains traceability after deletion of bulk data

Structure Security protects Partner, OEM, Supplier IP

Structure Import & Validation

Reuse & modification of structures

Enterprise Computing

Compute Services Interface

Enterprise Computing 3rd PartyCAE

Spread

Patran

SimManagerSimManager –– the CAE Integration Platformthe CAE Integration Platform

• Simulation Content Management • Tight integration with MSC products• Open integration with 3rd party tools

• Open integration with HPC• Open integration with PDM• Manage and Distribute Best Practices


Enterprise Services Interface

PDM ERP Reqts Test

Open Integration

SpreadSheets

In-HouseApps

MaterialsData

ProductivityApps

Open Integration

SimDesigner

EASY5

SimXpert

Adams

MS

C Integration

SimulationContent

ManagementPedigree SearchCollaborate

Content & ProcessSynergy

AutomateMethods Templates


IMPLEMENTATION IMPLEMENTATION APPROACHES AND APPROACHES AND ACHIEVEMENTSACHIEVEMENTS

Audi Audi -- Complex Complex Automotive CAE ProcessAutomotive CAE Process

Pre-Processing Solving Post-Processing Reporting

ModelsMeshes

PlotsCross sectionsMoviesImagesValues

Assemble reportCompare and annotatePost-processing resultsMovie-merges


Load Cases

Pre-ProcessingApplications

Values

IndividualFiles

Input

Decks

ComputeApplications

Simulations

Output

Decks

Post-ProcessingApplications

Solver

Model AssemblyModel Assembly

• Simulation Variant Configurator automates Model Asse mbly• Dramatically accelerates iterations • Enables remote, secure job submission

Data


Load

case

s

50% of users are-remote-not Audi employees

Process & Data Process & Data -- Managed & AccessibleManaged & Accessible

Pre-Processing Solving Post-Processing Reporting

ModelsMeshes

PlotsCross sectionsMoviesImagesValues

Assemble reportCompare and annotatePost-processing resultsMovie-merges

Meshes Assemble Model Cross-Section

Curve

CreateReport


Load Cases

Pre-ProcessingApplications

Values

IndividualFiles

Input

Decks

ComputeApplications

Simulations

Output

Decks

Post-ProcessingApplications

Solver

CombineLoadcase

InputDeck

Solve Output

Extract(Postprocessor)

Section Report

Report

Story-board

Audi Audi SimManagerSimManager Implementation MetricsImplementation MetricsSimulations in CAE-Bench

180.000

200.000

220.000

240.000

260.000

280.000

300.000

320.000

16.000

18.000

20.000

22.000

24.000

26.000

28.000

30.000

overall per month

2x throughput increase |based on advanced SimManager capabilities:- Variant Generator- Process Sequences

�Increased car lines 9 -> 35 with same team size�6 times more simulation at same cost�Expanded simulation into multi -disciplines (4 to 15)

Audi:


Josef Reicheneder, I/ET-83 CAE/CAT Processes, Methods, CAE-Bench at Audi, 31. Juli 2008

0

20.000

40.000

60.000

80.000

100.000

120.000

140.000

160.000

Jan-

03Apr

-03

Jul-0

3Oct-

03Ja

n-04

Apr-0

4Ju

l-04

Oct-04

Jan-

05Apr

-05

Jul-0

5Oct-

05Ja

n-06

Apr-0

6Ju

l-06

Oct-06

Jan-

07Apr

-07

Jul-0

7Oct-

07Ja

n-08

Apr-0

8Ju

l-08

Oct-08

Jan-

09Apr

-09

0

2.000

4.000

6.000

8.000

10.000

12.000

14.000

16.000

3x

3x throughput increase per analystbased on standard data and process management

2x

�Expanded simulation into multi -disciplines (4 to 15)

SimManager at GKN DrivelineSimManager at GKN Driveline

�Cut proposal time from weeks to days�Empower designers to simulate with proven procedure s�Captures knowledge: 11 global engineering centers


�Captures knowledge: 11 global engineering centers�Available 24x7, single global system�Justified by reducing physical testing

Minter,Steve Valine,Glenn Simulation Knowledge Management in GKN Driveline NAFEMS Seminar: „Simulation Data Management - Integration into the Product Development Process“ March 18 - 19, 2009 Wiesbaden, Germany


VALUE AND ROIVALUE AND ROI

The 3 Vectors of Business ValueThe 3 Vectors of Business Value

– Process Effectiveness• Getting the right effect, on time • Delivering certainty, reducing risk

– Process Efficiency• Getting there with less resources

– Product Innovation

Effecti veness

Innovation

Efficiency


– Product Innovation • Pushing the Performance Envelope (Features, Cost, Quality, Time To

Market,..)

The three vectors provide different Returns, calculated in different ways, to different organisations

Process EffectivenessProcess EffectivenessSimManager’s Structured Information Model provides:• Navigation to data – reducing search times• Automatic Audit Trail creation - less admin• Ability to supervise remote working – multi-site

and outsourcedenables:

Effect iveness

Innovation

Efficiency


enables:• Automation of laborious processes

Process EfficiencyProcess Efficiency

• Process Automation, enabled by SimManager– Model Assembly and Load-case setup, especially for

iterative analyses– Results extraction, less effort– Automated Report Generation, less effort– Easier Re-Use of data

enhances Analysts‘ Productivity by up to 35%• Emphasis on elimination of low added value, laborious

Effecti veness

Innovation

Efficiency


• Emphasis on elimination of low added value, laborious tasks to enable Analysts to spend their time on high added value engineering

• SimManager AutoPortal creates up to 100 data and key result objects from a complex simulation, saving analysts valuable time, hours per simulation

• Results are viewable in a browser, immediate access to results increases efficiency of all staff

Product Development & InnovationProduct Development & Innovation

Increased Simulation Capacity enables• Development of more products• Development of Innovative Products thru

– Simulation of more design options– Different simulations– More complex simulations

Effecti veness

Innovation

Efficiency


– More complex simulations

• Improved First-To-Market Capability• Benefit is greater sales and/or margins• Business/Program Managers own these numbers

ROI, When to Invest?ROI, When to Invest?

• Automotive OEM– 250 analysts x 35% productivity gain x 130,000€pa = €11M per annum once fully

deployed– Hard savings fully justify SimManager AutoPortal– Investment cost is reduced by new functionality & configurability from production

experience (SimManager AutoPortal)

• Organisation with 50 Analysts, iterative processes– Potential hard savings of ~€2M per annum once fully deployed


– Potential hard savings of ~€2M per annum once fully deployed– SimManager is becoming an attractive investment for such companies– Experience of 2 recent projects in Europe

• Small and Medium Enterprises– core simulation process and data management is becoming affordable in 2011

• Business consulting teams can help with justification– Best justification is (sadly) a business project/program/product failure with well

defined cost impact

A decade of A decade of SimManagerSimManager SPDM deploymentSPDM deployment


Thanks to these companies for presenting and publishing their experience with NAFEMS

Managed Simulation makes the DifferenceManaged Simulation makes the Difference

• BMW – a decade of SPDM drives product performance

• 0-90 in 8s, 4.1 l/100km, 109gCO2/km• Moving to the next level with Auto

Portal

320d EfficientDynamics


• Audi – 6 times increase in simulation throughput

• Expanded from 9 to 35 model lines

• SimManager-based Process Automation eliminates laborious tasks and drives up productivity

with thanks to the teams at BMW & Audi

Thank you for your attention

[email protected]

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