Jon Long – Director, Western Region Shyam S. Kumar – Sr...
Transcript of Jon Long – Director, Western Region Shyam S. Kumar – Sr...
Integrating Cost Analysis into the Product Development Process
Jon Long – Director, Western Region
Shyam S. Kumar – Sr. Professional Services Engineer
Engineous Proprietary Information
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
Engineous Proprietary Information
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
Engineous Proprietary Information
Product Development Challenges
Manual Iterative ProcessTime consumingError proneQuestionable qualityFewer designs
Iterative Process
Geometry Structural Fluid Cost
Update Models Run Simulation Review Results
Engineous Proprietary Information
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
Engineous Proprietary Information
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
Engineous Proprietary Information
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.
Engineous Proprietary Information
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
Engineous Proprietary Information
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
Engineous Proprietary Information
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
Engineous Proprietary Information
iSIGHT-FD: Integrated PD Workflows
Drag & DropCut & PasteRight-click menuMulti-Level/NestedConditionalParallel
Components
“Simflow” Capabilities
Product Development Workflow
Engineous Proprietary Information
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.
Engineous Proprietary Information
– 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
Engineous Proprietary Information
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
Engineous Proprietary Information
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
Engineous Proprietary Information
Live Demo: Typical Mechanical PD Process
GoalMinimize WeightMinimize CostEnsure part does not
fail under applied load(Stress < 250 Mpa)
Design VariablesGeometry Parameters
Engineous Proprietary Information
Live Demo: iSIGHT-FD Integrated Work Flow
Multi-disciplinary ProcessCAD (UG NX)Cost (SEER MFG)CAE (ANSYS)Visualization (VCollab)
Engineous Proprietary Information
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:
Engineous Proprietary Information
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