Simulation Software

The Benefits of Simulation Software

Simulation software enables greater design and process analysis early and throughout product development. Design engineers can reduce iterations, innovate faster, and accelerate time to market. Cost engineering can identify cost outliers quickly to eliminate overruns and ensure a profit margin. Sourcing can compare suppliers throughout various global regions to determine the most efficient and cost-effective ones. The factory floor can simulate manufacturing processes and get insights, including process cycle time calculation, tooling costs, and material utilization.

How Simulation Software Works 

Simulation software empowers manufacturers with more accurate cost projections. This, in turn, facilitates design optimization and more cost-effective production methods. The process of simulation works as follows:

1. Data Input: Users can input detailed information about a part or assembly for cost estimate purposes. The more detailed input, the better. Examples include material specifications, geometry, manufacturing processes, and production volumes.
2. Cost Models: Simulation software typically uses predefined, industry-standard cost models. Examples include labor rates, material costs, machine time, and overhead expenses.
3. Simulation: Manufacturing processes are then simulated virtually. The cost of each product development stage (raw material to finished product) is calculated.
4. Insights and Recommendations: Users then receive a cost breakdown and cost outliers, which they use to consider the most cost-effective design alternatives. They can adjust parameters (e.g., material selection, and production volume) to optimize costs and the design.

A key advantage of simulation software is the ability to estimate manufacturability and costs early in product development. As a result, design iterations are reduced, costs are lowered, decisions are made faster and better, and time to market is accelerated.

How Can Simulation Software Ensure Accuracy?

The more comprehensive and substantiated the input data is, the more precise the outcomes in terms of cost estimation and manufacturability. Although predefined cost models (e.g., labor rates, machine efficiency, etc.) are based on industry standards, real-world variables can influence their accuracy.

Additionally, more complex geometries and manufacturing processes tend to be less accurate than more straightforward parts.

It should be noted that regular calibration and updating of cost models is imperative to yield an accurate result. Factors such as inflation, material shortages, and other industry changes can impact costs over time. Moreover, comparative analysis across different scenarios (e.g., alternative materials, production volumes, different suppliers, or production regions) can improve accuracy when comparing estimates.

Although no estimate will be entirely accurate, the above measures can help manufacturers make more informed decisions.

What Should We Consider With Simulation Software?

When considering simulation software, there are many factors:

1. Benchmarking: Look for software that allows you to compare its estimates with historical data or actual production costs for similar parts. Consistency between those factors instills confident decision-making.
2. Prototyping and Testing: Ensure that prototypes can be created and tested in an actual manufacturing process. The actual production cost data can then be compared with estimated costs.
3. Supplier Feedback: Consider software that enhances supplier/manufacturer collaboration. Supplier insights on pricing and capabilities will help validate estimates.
4. Sensitivity Analysis: Seek out software that allows users to change parameters (e.g., material choice, production volume) that can influence cost estimates. The sensitivity analysis will highlight critical cost drivers.
5. Iterative Refinement: Get software that enables the continuous update of cost estimates with each design iteration. It will provide greater cost accuracy throughout product development.
6. Dynamic Updates: Secure software that enables users to adjust input parameters ad hoc to address unexpected production changes that affect cost (e.g., labor or material rate fluctuations).
7. Scenario Analysis: Factor in the ability to run various scenarios to see how alternative materials, processes, or production locations influence costs.
8. Re-Estimation: Require software that regularly updates data that can influence costs (e.g., supply chain disruptions and design modifications) so that users can re-estimate.
9. Risk Assessment: Explore software that provides cost-sensitivity insights, enabling users to identify and assess risks associated with unexpected issues.

Simulation software can position manufacturers to proactively mitigate disruptions, optimize manufacturability, lower costs, accelerate time to market, and ensure resiliency.