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Marc Halpern, P.E., Ph.D.
Research Vice President
Manufacturing Advisory Services
Model-Based Engineering: Opportunities, Risks, and Best Practices
Model-Based Engineering
1
Using idealized representations of technical content as significant support of engineering reasoning, evaluating, decision making, and creating.
The representations and the infrastructure that supports them are convenient for sharing, collaborating, adapting, innovating, and re-using
Key Issues
• What economic, business, and technology factors currently make model-based engineering a significant opportunity?
• What are today’s major challenges at enabling model-based engineering?
• What top priorities for planning model-based engineering and best practices for implementing it?
2
Key Issues
• What economic, business, and technology factors currently make model-based engineering a significant opportunity?
• What are today’s major challenges at enabling model-based engineering?
• What top priorities for planning model-based engineering and best practices for implementing it?
3
Organizations Need Agility to Address Changing Global Business Conditions
http://www.rand.org/publications/randreview/issues/2011/winter/world.html
Changing Demographics
Organizations Need Agility to Address Changing Global Business Conditions
Uncertain Materials Pricing
Fragile Global Economy
Source: http://www.emergingtextiles.com Source: The Association of Chartered Certified Accountants(ACCA),
Global economic conditions survey report: Q2, 2012
Source: U.S. Energy Information Administration, U.S. Bureau of Labor Statistics
Embedded Software Increases Complexity of Product Design and Quality Risks
Cars Smart Devices
Even Computerized Clothing
http://electronics.howstuffworks.com/gadgets/high-tech-gadgets/computer-clothing.htm
Suppliers and Partners
Hardware Software
Applications Middleware Embedded
HPU/GPU Will Further Accelerate Ongoing Hardware Price / Performance Advances
Source: Jon Peddie Research, 2012
Enabling Software Markets are Growing and Maturing
Maturing Market of Commercial Vendors with Ongoing Innovation
Scale
Scope
Small Enterprise Large Enterprise
Engineering-Centric
Corporate and Back Office
Specialty Engineering Vendors
Ansys, MSC, ESI, Mathworks Altair, Ansys, MSC, ESI, Mathworks
Maturing Market of Commercial Vendors with Ongoing Innovation
Dassault Systemes,
PTC Siemens
Scale
Scope
Small Enterprise Large Enterprise
Engineering-Centric
Corporate and Back Office
Specialty Engineering Vendors
Ansys, MSC, ESI, Mathworks Altair, Ansys, MSC, ESI, Mathworks
Maturing Market of Commercial Vendors with Ongoing Innovation
Dassault Systemes,
PTC Siemens
Scale
Scope
Small Enterprise Large Enterprise
Engineering-Centric
Corporate and Back Office
Autodesk
Specialty Engineering Vendors
Ansys, MSC, ESI, Mathworks Altair, Ansys, MSC, ESI, Mathworks
Maturing Market of Commercial Vendors with Ongoing Innovation
Dassault Systemes,
PTC Siemens
Scale
Scope
Small Enterprise Large Enterprise
Engineering-Centric
Corporate and Back Office
Autodesk
Specialty Engineering Vendors
Ansys, MSC, ESI, Mathworks Altair, Ansys, MSC, ESI, Mathworks
Maturing Market of Commercial Vendors with Ongoing Innovation
Oracle
SAP
Dassault Systemes,
PTC Siemens
Scale
Scope
Small Enterprise Large Enterprise
Engineering-Centric
Corporate and Back Office
Aras, Selerant, Sopheon, other specialty PLM
vendors, Microsoft
Autodesk
Specialty Engineering Vendors
Altair, Ansys, MSC, ESI, Mathworks
Virtual and intellectually driven
Physical and transaction driven
Positioning MbE and MbM in the Business Application Landscape
MES
ERP Financials &
Material Flows
Order
Product to Ship
Production
PLM Products
Virtual and intellectually driven
Physical and transactionally driven
Orders and Cash
Fulfillment
SCM Suppliers Product Requirements
Life cycle Support
Positioning MbE and MbM in the Business Application Landscape
Market requirements and analytics
Response to market
opportunity
CRM Customers
Parts and materials Orders
and Cash
Positioning MbE and MbM in the Business Application Landscape
Product Requirements
Lifecycle Support
Orders and Cash
Fulfillment
Fulfillment
MES
Design content, history, eBOMs Product
performance analytics
Customer BOMs
MRO status/needs
Orders
Parts & materials
MRO needs
Fulfillment,service BOMs
Virtual and intellectually driven
Physical and transactionally driven
ERP Financials &
Material Flows
PLM Products
SCM Suppliers
CRM Customers
Orders and Cash
MbM
MbE
Production
Positioning MbE and MbM in the Business Application Landscape
Product Requirements
Lifecycle Support
Orders and Cash
Fulfillment
Fulfillment
MRO Service
Design content, history, eBOMs Product
performance analytics
Customer BOMs
MRO status/needs
Orders
Parts & materials
MRO needs
Fulfillment,service BOMs
Virtual and intellectually driven
Physical and transactionally driven
ERP Financials &
Material Flows
PLM Products
SCM Suppliers
CRM Customers
Orders and Cash
MbM
MbE
Key Issues
• What economic, business, and technology factors currently make model-based engineering a significant opportunity?
• What are today’s major challenges at enabling model-based engineering?
• What top priorities for planning model-based engineering and best practices for implementing it?
18
Key Model-Based Engineering Challenges That Organizations Face
• Change management
• Knowledge transfer
• Defining data architecture
• Redundant application architectures
• Data/drawing/document synchronization
• Synchronizing role-based views of content
• Sharing data
• Enabling models with sufficient fidelity for needs
• Defining user environments (e.g. 2D/3D harmonization)
19
Management Challenges Deploying PLM Are Relevant to ERS
Question: How would you characterize the potential/actual impact of
these managerial challenges on your PLM implementation?
0 1 2 3 4 5
Lack of executive sponsorship
Project management challenges
Scope creep
Budgetary constraints
Cultural resistance
Underestimating the effort/resources
Ingrained business processes
Importance
Na
ture
of C
ha
lle
ng
e
Not Important
Project-Threatening
n=62
Technical Challenges Deploying PLM are Relevant to ERS
Question: How would you characterize the potential/actual impact of
these technological challenges on your PLM implementation?
0 1 2 3 4 5
Inadequate IT infrastructure
Problems integrating with existing IT applications
Lack of consensus and standards for NPD data
Data integration problems
Lack of consensus and standards for NPD processes
Importance
Na
ture
of C
ha
lle
ng
e
Not Important
ExtremelyImportant
n=62
Discordant Formats Will Make Software Support of ERS Challenging
Mergers and acquisitions
Multiple design applications
Partners and suppliers
MRO providers
Customers Legacy data
Upgrading Software Can Be Like Re-Wiring Your House with the Electricity On
Adapting to changing
business needs
Linking legacy data and applications
Serving expanding user
communities
Maintaining business
operations
Containing costs Scope Creep
Training
Key Issues
• What economic, business, and technology factors currently make model-based engineering a significant opportunity?
• What are today’s major challenges at enabling model-based engineering?
• What top priorities for planning model-based engineering and best practices for implementing it?
24
Systems Engineering and Requirements Mgmt. Take “Center Stage” for ERS
Math Modeling/Systems Engineering Software
Simulation and Test Data Management
Software
MCAD/ECAD/xCAE Software
PLM/(PDM)
PLM/(PPM)
Requirements Mgmt. Software/Systems Req. Mgmt. Hardware/Systems
Application Lifecycle Mgmt. (ALM )Software
/SW Dev.
Database (Predicted Potential Risks/Recorded Defects)
Root Cause Analysis (e.g. FMEA/FRACAS/Six Sigma
Systems Engineering and Requirements Mgmt. Take “Center Stage” for ERS
Math Modeling/Systems Engineering Software
Simulation and Test Data Management
Software
MCAD/ECAD/xCAE Software
PLM/(PDM)
PLM/(PPM)
Requirements Mgmt. Software/Systems Req. Mgmt. Hardware/Systems
(e.g. PTC MKS,
IBM Rational)
(e.g. DS Enovia, PTC PDMLink, Siemens
Teamcenter)
(e.g. Mathworks Matlab, Simulink)
(e.g. Altair, Ansys Cadence, DS, PTC Creo,
Mentor,)
(e.g. PTC ProjectLink, Planview, Sopheon)
(Note: Other apps such as Cognition, Relex, enhance these functions)
(Note: Cognition apps enhance these functions)
(e.g. Altair, Ansys EKM, DS SDM, MSC)
(e.g. Cognition,DS, PTC MKS, IBM, Siemens)
Application Lifecycle Mgmt. (ALM )Software
/SW Dev.
Database (Predicted Potential Risks/Recorded Defects)
Root Cause Analysis (e.g. FMEA/FRACAS/Six Sigma
Key Technology Adoption Risks
27
Technology maturity
Corporate readiness
Extent of learning
curve
Lessons Learned From Best PLM Software Deployments Apply to CAE
Business Priorities
IT Priorities
Lessons Learned From Best PLM Software Deployments Apply to CAE
Business Priorities
IT Priorities
Best chance of deployment
success
Prime Directive – "Lean Thinking"
Fulfill Customer-Perceived Value
Configurational Thinking
Leveraging Configurational Thinking and Lean Principles
Best Practice: Lean Thinking for CAE
Lean Principles
Elevate Customer Perceived Value
Lean Business Practices
CAE Software
Requirements
Lean IT Practices
Internal Customer Priorities
• Software performance
• Access to CAE applications
• HW/SW infrastructure costs
• Access to data/models/other content
External Customer Priorities
• Product reliability
• Product quality
• Timeliness to market
• Product cost
All Investments and Activities That Do Not Deliver Value Are Waste
Best Practices Uncovered from PLM Deployments Apply to ERS
No. Best Practice Manufacturer Benefits Achieved
1 Focus on building business
capability at the mindset layer
U.S.-based healthcare
manufacturer
More systematic team-centric NPD
processes with less dependence on
skilled individuals
2 Mind-set layer of "macro" level
elements
International beverage
company
Instituted phase-gate process, yielding
major quality advances
3 Evangelize the "configuration"
mind set broadly
Parts and equipment
supplier
Removed redundancy from product
portfolio accelerated growth
4 Don't outsource configurational
thinking
Parts and equipment
supplier
Clear corporate thought leadership
cultivated greater global cooperation
5 Triangular governance for IT
implementation activities
Apparel and footwear
company
Streamlined NPD processes yields
shorter time to market
6 Engage suppliers in the PLM
business transformation
European machinery
manufacturer
Reduced incompatible and redundant
product data improved NPD
collaboration
7 Continue configurational thinking
during change management
U.S.-based healthcare
manufacturer
Helped institutionalize processes for
capturing and reusing produce content
This research was conducted in collaboration with Satish Nambisan, Lally School of Management, Rensselaer Polytechnic Institute and Robert G. Fichman Carroll School of Management ,Boston College
32
Top 13 CAE and Simulation Opportunities
32
Broadly Recognized
Evolving
Nascent-Emerging
Transformational Significant Incremental
Impact on Design Success
Maturity
Moderate
Highest
Lowest
Challenge to Adopt
33
Top 13 CAE and Simulation Opportunities
33
Broadly Recognized
Evolving
Nascent-Emerging
Transformational Significant Incremental
Impact on Design Success
Maturity
Moderate
Highest
Lowest
Challenge to Adopt
CAD integration
Multi-sensory feedback
Adapt gaming technology
34
Top 13 CAE and Simulation Opportunities
34
Broadly Recognized
Evolving
Nascent-Emerging
Transformational Significant Incremental
Impact on Design Success
Maturity
Moderate
Highest
Lowest
Challenge to Adopt
Advanced materials modeling
MEMS/nano simulation
Error estimation and control
Analytics
Simulation/test data management
Optimization
CAD integration
Multi-sensory feedback
Adapt gaming technology
35
Top 13 CAE and Simulation Opportunities
35
Broadly Recognized
Evolving
Nascent-Emerging
Transformational Significant Incremental
Impact on Design Success
Maturity
Moderate
Highest
Lowest
Challenge to Adopt
Systems simulation
Stochastic simulation
Complexity analysis
Multiphysics simulation
Advanced materials modeling
MEMS/nano simulation
Error estimation and control
Analytics
Simulation/test data management
Optimization
CAD integration
Multi-sensory feedback
Adapt gaming technology
Summary
• What factors currently make model-based engineering a significant opportunity?
-leverage evolving technology to accelerate engineering and transfer knowledge
• What are today’s major challenges at enabling model-based engineering?
- Change management; consensus on data architecture; evolution to a new data architecture and infrastructure
• What top priorities for planning model-based engineering and best practices for implementing it?
- Aligning technical opportunities to business priorities tempered by risk factors
36
