How can design engineers balance conflicting time, cost, and quality goals?
As businesses and products grow in complexity, design engineers have much to consider to produce optimal product designs. This is particularly true for smaller and medium-sized businesses (SMBs) that struggle with the same challenges as their larger counterparts, but have fewer resources to address them. What are the most successful SMBs doing to manage this? This research explores this question.
Based on a survey of 230 respondents, this research study examines engineering practices and simulation use. It identifies how executives at SMBs (companies with revenues less than a billion US dollars) can realize higher development returns through simulation-driven design, which should lead to increased profitability.
Please enjoy the summary* below. For the full research, please visit our sponsor, Siemens (registration required).
Table of Contents
- Executive Summary
- What Does Product Success Mean?
- Business Complexity Creates Engineering Challenges
- Product Complexity Complicates Engineering Decisions
- Identifying Top Performers
- How to Address Growing Complexity
- Addressing Complexity with Technology
- Use Simulation throughout All Lifecycle Stages
- How to Adopt Simulation-Driven Design
- The Business Value of Simulation-Driven Design
- Recommendations
- About the Research
- Acknowledgments
Executive Summary
Increasing Complexity
Engineers have much to consider to design products with the best chance of market success. Products must be high quality, economical, and fast to market. However, as business environments and products become more complex, old ways of working may no longer be enough. Engineers need better methods to navigate the complexity of their engineering and design decisions to meet their goals. This can be especially challenging for a resourced-constrained smaller or medium size business (SMB).
What SMB Top Performers Do
Despite this complexity, Top Performers have implemented practices that allow them to be 2.1 times more likely to have highly effective processes to understand trade-offs. To achieve this, they increase their use of simulation and invest in more software capabilities. Unlike their less successful competitors, they leverage simulation throughout the entire product development lifecycle, supporting a simulation-driven design approach. In fact, SMB Top Performers are 75% more likely than Others to use simulation at the concept phase, and they continue to use it from this early stage through testing.
This is such a powerful approach that 99% of SMBs using simulation to explore design ideas report finding value. They report benefits such as better products, greater productivity, faster innovation, and a higher return on their development investments.
The Right Solution
Part of successfully adopting this approach requires using the right solution and technology. Design engineers report that CAD/CAE integration and embedding simulation inside CAD are the most important solution qualities to support their use of simulation.
This Research Report
This report shares research findings that provide an in-depth look at why today’s engineers at SMBs have so much more to consider than they did even just ten years ago. Design decisions are even more complicated, and simply relying on experience is no longer sufficient. The research reveals what the most successful SMBs do to address this, helping them to release more successful products and improve their profitability.
Product Complexity Complicates Engineering Decisions
Significant Product Complexity
While business complexity has created a challenging environment, the products have also become more complex, creating even more difficulties for engineers. The graph shows the top sources of product complexity. Much of this complexity comes from increased requirements.
More Requirements
With increased regulations, engineers have more safety requirements to deal with. As we saw earlier, quality is critical to product success, and this is driving more quality requirements. Customers also expect high performance, which is vital for competitive differentiation. Yet, innovation requirements have increased the number of components and systems, creating more factors to consider and making it even harder for engineers to understand the impact of their decisions. They need better ways to understand this to optimize designs and avoid inadvertently introducing errors. They also need to validate and verify requirements.
Getting this insight as the engineer works on it is the most efficient use time, especially compared to waiting weeks or months for physical test results when the design details are no longer fresh in the engineer’s memory. Not to mention, the later it is in the design process, the more a design has solidified, meaning changes will impact far more components. Any error or overlooked impact will result in errors that can increase costs, cause delays, and hurt quality.
More Configurations
Finally, as companies need to appeal to various market and customer needs, engineers must manage multiple product configurations. Each variant must also meet safety, quality, and performance requirements, adding further complexity while increasing the risk of missing the mark on critical product success factors.
How to Adopt Simulation-Driven Design
Integrated Design and Analysis
Regardless of performance, design engineers agree on what helps them use simulation the most. Integrated simulation and design tools and simulation embedded inside CAD are the commonly identified features. These features make simulation more accessible to design engineers and provide a way to access the functionality without disrupting their workflow. Plus, engineers stay in a familiar environment.
Integrated Test and Simulation
Beyond making simulation easier to access, most design engineers also appreciate when simulation and test are integrated. As discussed previously, this can help reduce test time. At the same time, engineering teams can benefit from access to test results to improve future simulation models to catch problems caught during physical testing.
Recommendations
Recommendations and Next Steps
Based on industry experience and research for this report, Tech-Clarity offers the following recommendations for SMBs:
- Consider the complex business environment in which engineers must work and ensure they have solutions to enable them to develop successful products. To be competitive in today’s global market, it is critical that products are high-quality, yet low cost and still get to market quickly.
- Understand the factors driving product complexity and empower engineers to navigate it with ways to understand the impact of their decisions so that they can optimize their designs. Simulation is the most common tool SMBs use to manage complexity as it can help balance competing criteria such as cost and quality, while guiding decisions so that products will be more competitive.
- Adopt or increase your use of simulation throughout design to support a simulation-driven design approach, starting at the concept phase, and continuing all the way to physical testing. Top Performers are 75% more likely than Others to start using it at the concept phase
- Use a solution that will empower design engineers to use simulation without disrupting their workflow with features such as CAD/CAE integration or embedded inside CAD, simulation and test integration.
*This summary is an abbreviated version of the ebook and does not contain the full content. For the full research, please visit our sponsor, Siemens (registration required).
If you have difficulty obtaining a copy of the research, please contact us.
