The New Product Development Paradigm Led by Simulation and Testing

2004-01-2667
The New Product Development Paradigm
Led by Simulation and Testing
Timothy J. Milburn International TechneGroup Incorporated
Copyright © 2004 SAE International
Product development and manufacturing organizations facilitate problem solving, evaluate multiple alternatives are moving from the traditional, multiple and serial and automate development and production. Some thdesign-build-test cycle approach to an integrated, have referred to this late 20 century paradigm as concurrent task and systems engineering paradigm, led "Digital Engineering". by upfront planning, analysis and simulation, supported by credible product test data. This "paradigm shift" However, in most cases, companies have only partially includes a move from a predominance of physical testing leveraged these tools, as they have not yet changed for product prototype validation to simulation-led problem many of their traditional development processes, and solving and performance validation, using Computer physical prototypes continue to be used as the primary Aided Engineering, and Design (CAE and CAD) tools. means of uncovering problems, rather than beforehand: during planning, concept design and detail design. Supported by use of Computer Aided Testing (CAT), Traditional companies today spend about 20 to 30% of physical testing capabilities have comparably grown in their development resource investments before starting accuracy and application range. The role of testing is detail design. moving from mostly pre-production validation to include support of product design decisions throughout the This approach typically leads to multiple additional development process, including upfront planning. design, build and test cycles and this approach remains mostly a sequential process. Some of these additional Section 1.01 development cycles result from introducing unvalidated new technology. Section 1.02 TRADITIONAL DEVELOPMENT PARADIGMS Even more risky is the desire of development teams to meet schedules, often releasing products to market before proper validation is completed - leaving end-In 1801 Gaspard Monge published "La Geometry users to discover undetected problems. Descriptive", a dissertation proposing the use of mechanical drawings (plan and elevation drawings to Today, a range of development capabilities exist within represent three dimensions) over direct construction of the range of more complex product companies (e.g. physical models. The paradigm shift was eventually vehicles) with regard to leveraging tools and optimizing embraced and over time mechanical drawings emerged process, from traditional to the new development as the standard in manufacturing. Physical models built paradigm that employs concurrent processes with from the drawings, nonetheless remained the primary significant upfront use of CAX tools. means to test design hypotheses. Figure 1 provides a conceptual time line of the Since the advent of CAE, CAD, CAT and other Traditional development approach. Figure 2 contrasts Computer Aided technologies (collectively called "CAX"), th this with a new paradigm in product development, as significant and broad changes from the 19 century explained below. paradigm have been made to greatly improve and standardize means to define and manage product data,
1 LaunchSerial "Multiple Design/Build/Test" EnvironmentPlanning ActualDesign Risk is High ReleaseMMiinniimmaall Build PlannedDDeevveellooppmmeenntt Release CompaniesOOccccuurrss HHeerree Test Struggle to Meet MarketTToooo MMuucchh Re-design & BusinessDDeevveellooppmmeenntt RequirementsFigure 1 && PPrroobblleemm SSoollvviinngg Re-buildOOccccuurrss HHeerree Re-test (Verification)
VOC Concurrent "Analysis Leads Design" EnvironmentLaunchConsiderableDevelopment & Prod. Planning Problem Solving Companies Lead in Occurs Here Planned Time to Market Target Setting & Actual & ProductivityReleaseConcept SelectionDetail DesignEvaluation Testing Build (Prototypes)(B/M, B/L, CUP) = PARADIGM SHIFTTest (Verification)
Risk is Low Figure 2 PARADIGM SHIFT IN DEVELOPMENT weight, and other targets. The goal is to assure a "hit product" before det... [download for more]