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Quantifying the Impact of Simulation Across the Product Life Cycle

May 9, 2023

Contributed by Area X.O simulation partner Ansys.

 

The overarching benefit of simulation is that it reduces time, cost, effort, and risk by identifying issues before they materialize in the physical world. Simulation also offers the ability to predict the performance of products, processes, and systems in a virtual environment, determine how they would behave in certain scenarios and provides engineers with the opportunity to fix problems before proceeding with the rest of the development process.

 

 

What is Simulation?

Simulation is a physically accurate virtual representation of a real-world product, process, or system. A simulation requires a digital model of the product, process, or system to be developed that is able to accurately capture the key characteristics, behaviors, or functions of the selected product, process, or system (including physics, chemistry and biology). In this way, the simulation can be validated against experimental data and then used to predict the performance of a product, process, or system either under specific discrete conditions or over time.

 

 

Have you ever experienced a simulation or digital twin?

Area X.O has just announced a new Simulation Discovery Portal powered by Ansys technology that provides a digital twin of its physical smart mobility testing facility. Innovators and entrepreneurs can now register for free to gain access to virtually interact with Area X.O’s assets. Registered users for Area X.O’s simulation community can learn about the benefits of simulation, see Area X.O assets in action, view examples of the virtual environment, and sign up to be informed about future information sessions and opportunities.

Visit the Simulation Discovery Portal and you can unlock your free access today.

 

 

Simulation software has long been established as a critical tool to help engineers tackle the top market pressures their businesses face. Best-in-class companies that invest in simulation know they are able to better tackle these pressures head-on, including:

  • meeting delivery deadlines,
  • differentiating products from competitors,
  • lowering costs across the product life cycle, and
  • delivering products on-time and on-budget.

In the current economic environment and with increased scrutiny of all company investments, simulation can create efficiencies within three key phases of the product life cycle (ideation / design / analysis, manufacturing, launch) as well as the compounded impact these have on the overall business metrics of the organization.

 

 

Reshaping the ideation, design and analysis process with simulation

At this stage of the product life cycle, the emphasis is on reaching production as quickly and cost effectively as possible. Companies are focusing their energy on using simulation to support early ideation and design, as well as the more traditional use in detailed design, verification, and validation. Companies utilize simulation feasibility studies to ensure the science and engineering make sense prior to development. After implementing a simulation solution, companies experienced material decreases in the length of development time and the number of expensive and time-consuming physical prototypes.

Designing and testing products in a virtual environment eliminates a large chunk of engineering expenses, especially if companies are handling expensive prototypes or making a large number of design changes requiring multiple iterations. Faster development, testing, and analysis all contribute to an overall decrease in time-to-market, enabling companies to get new products out the door in less time and with fewer costs. Simulation is an agile platform that allows innovator to experiment with drastic changes to design and pivot the product scope with minimal risk. This greater speed of innovation at a lower cost helps companies deliver high-quality products to their customers despite reduced development budgets.

 

 

Enhancing manufacturing processes with simulation

The next step in the product life cycle that simulation influences is manufacturing. The ability to run more tests at little to no extra cost allows engineers to perfect their designs before sending them to manufacturing, which reduces the number of engineering change orders.

 

Did you know?

Simulation is a physically accurate virtual representation of a real-world product, process, or system. A simulation requires a digital model of the product, process, or system to be developed that is able to accurately capture the key characteristics, behaviors, or functions of the selected product, process, or system (including physics, chemistry and biology). In this way, the simulation can be validated against experimental data and then used to predict the performance of a product, process, or system either under specific discrete conditions or over time.

 

Detailed simulation models allow engineers to accurately relay the materials and systems required for production to manufacturing teams. Having a more comprehensive bill of materials (BOM) helps optimize raw material utilization, and greater efficiency in design phases spills over into manufacturing by improving complete and on-time shipment rates. Simulation usage minimizes the iterations within the manufacturing cycle and helps businesses launch new product lines in a timely manner, ultimately gaining customer trust and influencing future sales.

 

Simulation Reduces Costs

Late-stage change orders can be extremely expensive and preventing them with simulation tools makes a big difference for companies looking for areas to cut costs.

In partnership with AutonomouStuff, Area X.O developed a bywire-enabled Lexus 450H that is a full functional autonomous vehicle utilized as a research and development tool. In addition to the physical prototype, the Area X.O Simulation Discovery Portal allows developers to test and validate technologies and algorithms in a multitude of real-world scenarios.

 

 

Experience the Discovery Portal for yourself – register now to gain access for free.

 

Impact of simulation at, and post, product launch

The faster time-to-market associated with simulation comes to fruition with the greater percentage of products meeting launch dates. Minimizing delays in early design phases, eliminating the time required to generate and work with physical prototypes, and optimizing manufacturability all contribute to getting products launched on schedule.

Reducing costs throughout design and manufacturing processes influence the greater improvements in cost and revenue targets. Simulation also impacts quality targets, as products are more carefully designed and tested in virtual environments before moving to production.

The impact of using simulation persists throughout the post launch life cycle of the product resulting in a significantly lower likelihood of product recalls and external failures. For long life cycle, highly engineered products that operate in relatively harsh environments, a company’s ability to realize these cost savings can be the difference between corporate success and failure.

Companies with simulation capabilities are experiencing 14% greater year-over-year cost savings from external failure costs (returns, warranty, recalls, etc.)

Avoiding immediate unnecessary costs within the factory as well as future unnecessary costs from returns and warranties allows companies to improve their customer relationships while reallocating funds reserved for external failure costs to more advanced initiatives.

Business leaders at companies with simulation capabilities are better able to plan and make decisions around new products and release plans based on efficiently created comprehensive design plans. The differences in operating margins and total cost per unit are connected to the overall cost savings associated with simulation. Decreases in the number of physical prototypes in design phases, increases in capacity and material utilization in manufacturing processes, and decreases in warranty and service fees combine to lower the total cost of generating a single unit. As each unit experiences a 22% greater decrease in cost per year, companies can significantly cut down on their development and operating costs, resulting in higher operating margins.

When using simulation, from ideation, design and analysis, manufacturing and operations, through to product launch and service, the cost and time savings associated with preventing design failures are evident at each stage in the process. When consolidated, these savings make a significant impact on the critical business key performance indicators of an organization. In today’s economic environment, it has never been more evident that leveraging the power of simulation enables companies to not only address immediate operational cost control imperatives but ensure they emerge stronger and more competitive than ever before.

 

Access the Area X.O Simulation Discovery Portal for FREE today.

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