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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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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?
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
– 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
• 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:
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
• 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
• ensure Traceability and Deliver Certainty
• SimManager has been delivering in production for a decade
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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:
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
�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 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
– 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
• 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
– 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
– 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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 201028
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
NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010NAFEMS EUROPEAN CONFERENCE ON SIMULATION PROCESS AND DATA MANAGEMENT 2010
• 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