Integrating Cost Analysis into the Product Development Process

Jon Long – Director, Western Region

Shyam S. Kumar – Sr. Professional Services Engineer

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Agenda

BackgroundChallenges & Opportunity

Engineous Product OverviewiSIGHT-FD/FIPER

Galorath Product OverviewSEER MFG

Live DemoIntegrate CAD, CAE, Cost Model & Visualization tools into iSIGHT-FD Workflow Configure and perform Design Trade-off Studies

Summary

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Typical Product Development (PD) Process

Concept Computer Model ObjectiveReduce

Cost$$ $$

NO YES

Final Design

Improve Quality

Analysis

Design MeetsRequirements?

Iterative Process

Geometry Structural Fluid Cost

Update Models Run Simulation Review Results

Reduce Weight

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Product Development Challenges

Manual Iterative ProcessTime consumingError proneQuestionable qualityFewer designs

Iterative Process

Geometry Structural Fluid Cost

Update Models Run Simulation Review Results

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Product Development Challenges

Multiple Disciplines & Product TeamsInteroperability

Applications/Tools don’t “talk” to one another

Data ManagementManual “over the wall” data transfer> Unreliable> Data not trackable

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Product Development ChallengesCost Estimation

Cost not tightly linked to CAD/CAE product dataDesign first, estimate cost later

Inability to estimate costs accurately up-frontLack of accurate costing of changes during PD

Concept Design Test Tooling

Typical Product Development CycleTypical Product Development Cycle

with DFM with CAI with DFM with CAI PlugPlug--InIn

Product Development Cycle

Greatest Potential Savingsusing DFM in this Phase

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Galorath: SEER MFG

Bottoms – Up Parametric Cost ModelBased on StandardsParametric ForecastingEstimates At the Process Level

Estimates Average Unit and Total Production costsLaborMaterialTooling

Bases Estimates on Part and Process ParametersPart Size, Process Types and Steps, Lot Size, Etc.

Provides Design Team with the ability to make smart decisions through all program phases,

Which Reduces Downstream Manufacturing Costs Provides the Design Team with Real Time Cost FeedbackProvides a Systematic Repeatable Estimating Process

Reports Production Cost estimates in a variety of formats

Provides Extensive Process Knowledge Base for “Should Cost” Analysis, even in the Absence of In-House Process Experts.

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Integrates disparate 3rd party or in-house softwareAutomates the iterative simulation processExploration to meet defined goals

(Federated Intelligent Product EnviRonment)Centralized Model and Component LibraryDistributed and Parallel Execution WebTop interfaceFederated B2B communication

Web-based, secureCollaborative engineering simulation environmentInter or intra-enterprise Protects intellectual property through federated process execution

Open API’s, components, plug-in, SDK, Web apis’s, JSP

Enterprise Infrastructure

Desktop Application

Engineous: iSIGHT-FD/FIPER Framework

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Integrated/Automated PD Process

Automated Design:Define simulation process, goals and constraints. Software Robot applies design intelligence via DESIGN DRIVERS.

Benefits:•Increased design evaluations•Repeatable process•Improved quality •Reduced cycle time•Greater product knowledge

OptimizationDesign of ExperimentsQuality EngineeringApproximations

Iterative Process

Geometry Structural Fluid Cost

Update Models Run Simulation Review Results

Software Robot

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iSIGHT-FD: Component Based Integration

CAD Model CAE Model CFD Model DB Model

AccessAccessAccess

Math Model

Internal Model

Fortran

Visual Basic

Java

C++

Unix scripts

Perl scripts

Tcl scripts

And more….

The iSIGHT-FD/FIPER framework provides “direct” interfaces to CAD, CAE, CFD, Cost, Math and other PD tools.

Cost Model

ExcelExcelExcel

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iSIGHT-FD: Integrated PD Workflows

Drag & DropCut & PasteRight-click menuMulti-Level/NestedConditionalParallel

Components

“Simflow” Capabilities

Product Development Workflow

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iSIGHT-FD: Automated Design Strategies

Y1

ConstraintBoundary

Y2

Initial Design

Search for solutionOptimization

(Approximations)

Robust/Reliability Design(Quality Engineering)

Feasible Infeasible (safe) (failed)

X2

X1

DOE:Critical Factors

And Initial Design

Flexible automated design exploration strategies combining DOE, surrogate models, stochastics & multi-objective optimization.

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– Approximation Visual Design Driver

– Engineering Data Mining (EDM)

– Correlation Mapping

– Interactive real time parameter monitoring

– 6-Sigma, DOE, Statistical post-processing

iSIGHT-FD: Visual Results Interpretation

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FIPER: Extensible and Scalable

FIPER ACS (Application Control Server):Share Tools, Processes and Analysis ResultsEasily distribute jobs to thousands of computer resourcesProvide simplified end-user access via Web clientFederated, Collaborative “B2B” with design partners

FIPER ACS (Application Control Server):Share Tools, Processes and Analysis ResultsEasily distribute jobs to thousands of computer resourcesProvide simplified end-user access via Web clientFederated, Collaborative “B2B” with design partners

Publish iSIGHT-FD Components and “SimFlows” to FIPER

Internet

Servers

Clusters

DesktopsLAN, WAN, VPN

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FIPER: Web Access to ModelsRun, Modify Design Drivers, and view results from FIPER WebTop client

Deploys “Out of the Box”, with no webpage programming or configuration required

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Live Demo: Typical Mechanical PD Process

GoalMinimize WeightMinimize CostEnsure part does not

fail under applied load(Stress < 250 Mpa)

Design VariablesGeometry Parameters

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Live Demo: iSIGHT-FD Integrated Work Flow

Multi-disciplinary ProcessCAD (UG NX)Cost (SEER MFG)CAE (ANSYS)Visualization (VCollab)

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Live Demo: Trade-Off Results Summary

Mass = 3.7kg (reduced 13%)Stress = 246MPa (reduced 64%)Cost = $223,155 (reduced 20%)

Optimized Design:

Mass = 4.24kgStress = 677MPa Cost = $279,645

Starting Design:

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Summary

iSIGHT-FD enables rapid integration of different tools & disciplines

Automated, Efficient & Repeatable PD ProcessReduced Cycle Time

iSIGHT-FD facilitates exploration of many more design alternatives

Optimized Design – Improved PerformanceRobust Product Design – Improved Quality

Integrating the SEER MFG cost model into the PD process helps make smarter decisions early and reduce cost !

Reduced Cost

Thank You !

Please visit www.engineous.com & www.galorath.com