9.3 APPLYING SIMULATIONS EFFECTIVELY
139
Number of Organizations with Similar Results
Softw are A
vailab le
b ut Not Used
Mak es Pretty Pictures
P erf
or ms Sim
ulations
after Design is Completed Predict and Correct
Prob lems Dur
ing Design
Correct Prob lems and
Optimiz e Design
Predict Prob lems
,
Optimiz e
, and V
alidate Effectiveness of Simulations
Figure 9.7 Qualitative illustration grouping the number of organizations to the
effectiveness of their simulation efforts.
in modeling as well as possess knowledge of the product’s func- tion and the processes used in manufacturing. The individual must
possess soft skills, as interaction is necessary between the design and manufacturing communities.
9.3.2 Planning
Effective use of computer simulations requires planning. Few or- ganizations, if any, have the resources to conduct simulations on
every product. Planning efforts should begin by identifying stra- tegic products. For these key products, the functions and processes
that are to be simulated must be defined. Depending on the com- plexity, multiple models may need to be run for each specific
function and process. For example, a structural component may need to have simulations run to model both stresses and fatigue
life. An additional set of simulations may be run by the high
140
VALUE ADDED SIMULATIONS OF DIE CASTING PROCESSES
integrity die casting supplier to optimize the process for the com- ponent. For each individual simulation, a goal must be defined as
well as a metric to measure success. Most product timelines clearly define the date a design must be
completed with fully dimensioned drawings and specification. When preparing a timeline, it is important to specify an earlier
date at which a design is to be ready for use in computer simu- lations. Multiple iterations of any given simulation are often nec-
essary when seeking an optimized design. Also included should be a time before design release to repeat simulations.
9.3.3 Coupling Product and Process Simulations
Often process simulations are conducted by suppliers after designs have been completed and formally sourced. In such cases, opti-
mization of the manufacturing process is limited to process parameters. The opportunity to modify the design to improve man-
ufacturability is lost.
Sharing design data with suppliers prior to design release with the purpose of conducting process simulation can result in signif-
icant improvements in manufacturability and reductions in cost during production. Formal drawings with complete dimensions are
not required to complete such activities. Raw three-dimensional computer-aided design CAD data are all that is required. In
many cases, results from the process simulation can be used to predict functional properties of the product as well.
9.4 COMMITMENT
When choosing to conduct simulations, an organization must be committed in order to be effective. Capable individuals must be
selected and dedicated to the task of computer modeling. Simu- lations must be conducted prior to the completion and release of
a design. An organization must plan for success.
9.5 A CASE FOR SHARING SIMULATION DATA
ACROSS ORGANIZATIONS
During the development of a structural component for an auto- motive chassis, a supplier and original equipment manufacturer
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