The Value of Simulation Process & Data Management – Lessons from a Decade of Production Experience Mark Norris MSC.Software
[email protected]
Agenda • • • •
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 2010
Business Challenges • Quote Customers Faster • Increase the accuracy of quotes for wins & margin • Reduce Physical Prototype Costs • Reduce Physical Testing Costs • Reduce Development Costs • Accelerate Product Introduction • Achieve Market leading Product Performance • Introduce more Products •MD …… Simulation-Based Development is the Answer NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
The Simulation Challenge Expanding Capacity, Managing Process & Data # of CAE Simulations Complexity of Simulations Data per Simulation
Nearshore/Offshore Development & Integration
Source: BMW
Driving Demand for Analyst Productivity NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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 files can I delete? •
Staff spend up to 50% of their time searching for data
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Globalization & 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Multi--Discipline magnifies the Challenge Multi • 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: Vehicle CAD Regime Option Config file
Aerodynamics Model File
Simulation CFD
Results Loads
Loads Input
Load State Geometry CAD Materials Composite
Stress Model File
Simulation MD Nastran
Results Stresses
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Partner 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 cannot risk disclosure of their proprietary know-how • Typical solution is manual exchange of data files, traceability and pedigree are defined in documents NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Engineering Organisations need: A global, secure SPDM platform to • manage Simulation data & process • enable collaboration, remote working, outsourcing and process automation • ensure Traceability and Deliver Certainty
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Manual approaches were necessary in the past due to a lack of appropriate Information Technology Where is that calculation?
SPDM is now available and proven
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
SPDM CAPABILITIES
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Managing the Simulation Environment Modeling & Assembly
Load Case Setup
Job Submit
Post-process Key Results
Create Reports
SimManager Process Management
12/1/2010
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010 12
What were the Inputs? the Process Parameters, the Outputs? the Key Results? ….. Structure provides the Answer NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Information Structures deliver Value Automated model assembly
Work In Progress Visibility
Validated Process Templates
Process Execution data
PostProcessing Automation
Results Traceability
Validated Material data
Automated Reporting of MachineReadable Structures
Validated meshes
Structure Import & Validation
Structure Security protects Partner, OEM, Supplier IP
Key Results Visibility
Immediate Audit Trail for Regulatory Compliance Reuse & modification of structures
Secure Structure access enables remote work & outsourcing
Structure maintains traceability after deletion of bulk data
WIP visibility enables 24/7 Global Collaboration
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
IMPLEMENTATION APPROACHES AND ACHIEVEMENTS NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Audi’s Challenge: develop more, better models
Numbers of Variants
Vorsprung durch technik A3/S3 A3 Sportback A3 Cabrio TT Coupé TT Roadster TTS Coupé TTS Roadster A4/S4/RS4 A4/S4/RS4 Avant A5/S5 A6/S6 A6/S6/RS6 Avant A6 Allroad A8/S8 R8 Q7 ...
Audi 80 Audi 100 Audi 80
Audi 100 Avant
Audi 100
Audi Cabrio
Audi Coupé
Audi Coupé
1980
1990
2000
2010
Model offensive for customer orientation and answer on tightened competition Source: AUDI / EC SIMDAT projet
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Audi - Complex Automotive CAE Process Approach: Elimination of low added value, laborious tasks to free up Analysts time Pre-Processing Meshes
Solving
Post-Processing
Models Plots Cross sections Movies Images Values
Reporting Assemble report Compare and annotate Post-processing results Movie-merges
Compute Applications Pre-Processing Applications Input Load Cases
Decks
Simulations
Output Post-Processing Applications Individual Decks Files Solver
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Model Assembly • Simulation Variant Configurator automates Model Assembly • Dramatically accelerates iterations • Enables remote, secure job submission
Loadcases
Data
50% of users are -remote -not Audi employees NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Process & Data - Managed & Accessible Pre-Processing Meshes
Solving
Post-Processing
Models
Meshes
Assemble
Loadcase
Curve Plots Cross sections Movies Images CrossValues Section
Model
Combine
Assemble report Compare and annotate Post-processing results Movie-merges
Create Report
Compute Applications
Report
Pre-Processing Applications
Extract Input
Load Cases
Reporting
Input DeckDecks Simulations
(Postprocessor)
Output Post-Processing Applications Solve Output Individual Decks Files Solver
Storyboard
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Audi SimManager Implementation Metrics 2009 Simulations in CAE-Bench 320.000
30.000 overall
300.000
per month
28.000
280.000
26.000
260.000
24.000
Audi:
240.000 220.000
Increased car lines 9 -> 35 with same team size 6 times more simulation at same cost Expanded simulation into multi-disciplines (4 to 15)
200.000 180.000
2x throughput increase | 22.000 based on advanced SimManager capabilities: 20.000 - Variant Generator 18.000 - Process Sequences 16.000
160.000
2x
140.000
14.000 12.000
120.000
3x throughput increase per analyst based on standard data and process management
100.000
10.000 8.000
80.000
3x
60.000
6.000
40.000
4.000
20.000
2.000
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Josef Reicheneder, I/ET-83 CAE/CAT Processes, Methods, CAE-Bench at Audi, 31. Juli 2008
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
SimManager at GKN Driveline
Cut proposal time from weeks to days Empower designers to simulate with proven procedures 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 NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
VALUE AND ROI
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
The 3 Vectors of Business Value – Process Effectiveness • Getting the right effect, on time • Delivering certainty, reducing risk
Effectiveness Efficiency
– Process Efficiency • Getting there with less resources
– Product Innovation
Innovation
• Pushing the Performance Envelope (Features, Cost, Quality, Time To Market,..)
Structured information systems deliver step change improvements in Process Effectiveness
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Process Effectiveness SimManager’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 outsourced enables: • Automation of laborious processes
Effectiveness Efficiency Innovation
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Process 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 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
Effectiveness Efficiency Innovation
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Product Development & Innovation Increased Simulation Capacity enables • Development of more products • Development of Innovative Products thru – Simulation of more design options – More simulation iterations – More complex simulations
Effectiveness Efficiency Innovation
• Improved First-To-Market Capability • Benefit is greater sales and/or margins • Business/Program Managers own these numbers
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
ROI • Return of a project depends on: – Industry processes – Company situation and challenges – Solution Maturity
• Investment depends on: – Diversity of Processes – Solution Maturity – Implementation Expertise Maturity (IT does matter)
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Returns on Process Efficiency • Process Automation, enabled by SPDM, can enhance Analysts‘ Productivity by up to 35% • 250 analysts x 35% productivity gain x 130,000€pa = €11M per annum once fully deployed • This total saving is achieved when an organisation requires extra simulation capacity for growth or to enhance product development
Effectiveness Efficiency Innovation
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Returns on IT Process Effectiveness • A Global SPDM system enables: – Consolidation of Hardware, Licenses, IT operations in a single centre, globally accessible 24/7, with lower IT costs – Orderly, prioritised queueing and job execution ensures high utilisation of hardware resources and licenses – Storage optimisation by better definition of “what can be deleted when” reduces storage costs
Effectiveness Efficiency Innovation
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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 – 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
A decade of SimManager SPDM deployment
Thanks to these companies for presenting and publishing their experience with NAFEMS
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NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Managed 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 NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
Thank you for your attention
[email protected]
