analysis planning & simulation data management...
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NAFEMS
Analysis Planning & Simulation Data Management, complementary techniques
to assure confidence in simulation results
Mark Norris, theSDMconsultancyAlthea de Souza, Quesada Solutions
Steve Howell, Abercus
NAFEMS
Mark Norris CEng MBA theSDMconsultancyPLM and SPDM Consultant• Engineering background: Simulation for machine dynamics,
crack propagation in aircraft, FE, MBS, CAD/CAM• 30 years experience of designing and delivering Leading Edge
Engineering IT solutions• Wide PLM expertise, industry sectors, solutions• 7 years in the SDM domain focusing on value, value analysis,
best practices, system selection, POCs, program governance• Delivery of SDM value analyses and SDM proofs of concept• Author of the NAFEMS white paper on the Business Value of
Simulation Data Management• Delivers NAFEMS SPDM Training Workshop (2 Days)
Mark Norris
NAFEMS
Agenda
• Introduction to assuring confidence• Simulation Data Management for assuring confidence• SDM adoption challenges• Analysis Planning for assuring confidence• Conclusion
NAFEMS
Introduction
• Confidence in Results is enhanced by Confidence in the Processes used to obtain them– CMMI scale is widely recognised for overall Process Maturity
for Integrated Product Development– ISO9001 certification is a necessity for certain industries
• PLM systems are extensively used to manage Change and Document Processes in regulated industries
• Simulation Process Data Management (SPDM) solutions have been available since 2000 but usage is limited
NAFEMS
Simulation is Challenging to Manage
• The simulation domain poses unique challenges in the assurance of confidence in results– Multi-dimensional problem– Many process steps– Every step impacts the results
• It’s so unique that a new type of data management had to be developed to manage Simulation Data-sets
• Simulation is continuously evolving– Into new domains– New methods (Benchmark January 2017)
NAFEMS
Requirements
Structure Definition + Geometry
Material models
Load‐cases, Regulatory & Performance
Process Definitions/Templates
System Definition & Parameters
Loads by Calculation or Measurement
Input data, intermediate data, process data & results data
Physical Test Results
Simulation Process Audit Trail
Discrete Solution
Discrete Models
Math Models
© 2017 theSDMconsultancy
NAFEMS - The International Association for the Engineering Analysis Community Essential Principles of SDM eL079 Session V1.0 Page 9
A Simulation Process is a chain of complex stepsDecisions & Assumptions made at each stage must be:– consistent – recorded
IDEALISATION• Physics• Geometry• Allowables
DISCRETISATION• De-featuring• Mesh• Loading
SOLUTION• Numerical
analysis
Discrete Solution
Discrete Models
Math Models
Physical System
© 2017 theSDMconsultancy
NAFEMS
Searchfor data
Submit & Solve
Extract & Post‐Process
Create ReportM
esh
Assemble
SDM: Directed Acyclic Graph to record simulation and process datawhereas core PLM data model = hierarchical product structures
© 2017 theSDMconsultancy
NAFEMS
CMMI Maturity Levels
Managed L2
Optimizing L5
Initial L1
Defined L3
QuantitativelyManaged L4
Processes continually improved through innovative & incremental technological improvements
Processes are measured & controlled, timing is predictable. Quantitative quality goals are set & met.
Processes are well characterised & understood. Specifications, peer review, version control
Processes are planned, documented, performed, monitored & controlled at the project level. Often reactive
Processes are ad-hoc, success depends on competencies & heroics of people. The person is responsible for the result.
L0Simulation to be deployed in this domain for the first time. Competencies, Methods, Processes need to be developed©theSDMconsultancy
CMMI = Capability Maturity Model Integration
NAFEMS
unreadable
12
NAFEMS
CMMI Maturity Levels
Managed L2
Optimizing L5
Initial L1
Defined L3
QuantitativelyManaged L4
Processes continually improved through innovative & incremental technological improvements
Processes are measured & controlled, timing is predictable. Quantitative quality goals are set & met.
Processes are well characterised & understood. Specifications, peer review, version control
Processes are planned, documented, performed, monitored & controlled at the project level. Often reactive
Processes are ad-hoc, success depends on competencies & heroics of people. The person is responsible for the result.
L0Simulation to be deployed in this domain for the first time. Competencies, Methods, Processes need to be developed©theSDMconsultancy
SPDM Progression• Optimise
frequently-used Processes
• Refine as Best Practices
• Identify Standard Processes for Use
• Identify Processes in Regular Use
• Record what the Analyst did as painlessly as possible
NAFEMS
• I’m confident this simulation is valid.
• For what it does, its representations are accurate enough.
• It does the right things, its representations are complete enough
• It represents the right entities and attributes.
• It works, trust me.• We have no idea of the
maturity
Mapping Maturity Models: H&Y(Harmon and Youngblood)
Managed L2
Optimizing L5
Initial L1
Defined L3
QuantitativelyManaged L4
Processes continually improved through innovative & incremental technological improvements
Processes are measured & controlled, timing is predictable. Quantitative quality goals are set & met.
Processes are well characterised & understood. Specifications, peer review, version control
Processes are planned, documented, performed, monitored & controlled at the project level. Often reactive
Processes are ad-hoc, success depends on competencies & heroics of people. The person is responsible for the result.
L0Simulation to be deployed in this domain for the first time. Competencies, Methods, Processes need to be developed
NAFEMS
Sandia Predictive Capability Maturity Model
• Six process steps to achieve confidence in Simulation Results for High Consequence Engineering Systems
• Underpinned by an SDM solution
15Oberkampf & Imbert NAFEMS NWC17
NAFEMS
CMMI Maturity of Simulation
Managed L2
Optimizing L5
Initial L1
Defined L3
QuantitativelyManaged L4
Processes continually improved through innovative & incremental technological improvements
Processes are measured & controlled, timing is predictable. Quantitative quality goals are set & met.
Processes are well characterised & understood. Specifications, peer review, version control
Processes are planned, documented, performed, monitored & controlled at the project level. Often reactive
Processes are ad-hoc, success depends on competencies & heroics of people. The person is responsible for the result.
L0Simulation to be deployed in this domain for the first time. Competencies, Methods, Processes need to be developed
SME Members, Small S&M Teams
High Maturity Auto OEM’s running 50 Virtual Prototypes daily or more often
High Maturity Auto Tier 1s running 500 Virtual Prototypes daily or more often
Members wideningUse of Simulation
© 2017 theSDMconsultancy
NAFEMS
SDM is a Proven, Robust Technology
• Pioneers are particularly successful• NAFEMS EUROPEAN SPDM CONFERENCE 2015: CELEBRATING 15
YEARS OF SDM IN PRODUCTION IN MUNICH• 2,000,000 complete vehicle data and results sets at BMW • 2,500 managed vehicle simulations per day• 1,800,000 simulations @ Audi• Successes in all sectors
– Auto, Aero, Nuclear, Rail, Oil,…• OEMs, tier 1 suppliers SMEs
BMW GroupMarc HertleinPage: 18
SheerDriving Pleasure
SPDM @ BMWContinuous Integration of SPDM
May 2013
Integrated simulation processes.
Skriptlibrary Skriptlibrary Report TemplatesHPC Interface
Configuration Assembly Solve Post process Reporting
~20000coresSpread over
Europe
Current Applications and Architecture.
NAFEMS
SDM for ISO9001 at• Abercus is a Consultancy specialising in Advanced
Engineering Simulation for the Energy Industries• Abercus developed an SDM called JET to retain precise records of every
simulation undertaken• JET, their in-house SDM tool automatically creates the simulation scripts,
post-processes and then stores the results • JET has saved time and effort at the point of use – and also provides the
information required for the Quality Management System (QMS) record, minimising duplication of effort
19Achieving ISO 9001 accreditation and the role of the NAFEMS QSS
NAFEMS
Saving time/effort at point of useEnsuring Quality and Traceability
JET – AN SDPM TOOL
*******************
**************
NAFEMS
SPDM adoption is limited
• SDM has very limited adoption by the 750,000 analysts worldwide, only 1 to 2% of engineers
• Whereas PDM or PLM adoption is nowv 90%+ in any industrial company using simulation
• Information system usage & deployment is new for Modelling & Simulation organisations (NAFEMS Survey), most Analysts still use the file system & logbook
• Digital Transformation like SDM and PLM is difficult, especially the first time
NAFEMS
Digital Transformation like SDM Requires• Executive Sponsorship
– The SDM program must deliver a Solution to the Key Initiatives/needs of the business
– Compatible with the Constraints of the IT landscape• Commitment and Time from Senior Staff
– To enable their key processes better, faster, cheaper• A Change Champion & Program Manager
– Transformation has to be evangelised and driven• High Level Technical SDM/IT Resources
– Specific Process and Productivity improvement require high level skills
• Funding; 100k€ to 1M€
NAFEMS
SPDM Deployment
• The first step in SDM deployment is to understand the planning and reporting requirements
• Valeo presented their PEN approach Plans d’ExpérienceNumérique in 2016 (Plans for a Numerical Experiment) – “Contract” between Engineering and Modelling & Simulation– Stored in a digital repository– Intellectual Property from Simulation can be searched/retrieved
• Stepping stone to SPDM
NAFEMS
Techniques to improve Capability Maturity
Managed L2
Optimizing L5
Initial L1
Defined L3
QuantitativelyManaged L4
Processes continually improved through innovative & incremental technological improvements
Processes are measured & controlled, timing is predictable. Quantitative quality goals are set & met.
Processes are well characterised & understood. Specifications, peer review, version control
Processes are planned, documented, performed, monitored & controlled at the project level. Often reactive
Processes are ad-hoc, success depends on competencies & heroics of people. The person is responsible for the result.
L0Simulation to be deployed in this domain for the first time. Competencies, Methods, Processes need to be developed
NAFEMS PSE certification
Analysis Planning
Simulation Process Data Management
© 2017 theSDMconsultancy
NAFEMS
Engineering
How approaches fit together
Experimentation Domain
Numerical Experimentation
L2‐L5 Simulation Data ManagementProcess Record + Data Record
Physical Experimentation(Test Data Management) Test Peporting
Analysis Record: Results &
Conclusions
L1‐ Analysis Management
Test Planning
Version Control is mandatory for L3 Maturity. Managing the Process Record Enables Process Improvement
L0‐ Prof. Sim. Eng. (PSE) Certification
Analysis Plan: Requirements & Record
NAFEMS
ANALYSIS PLANNING AND REPORTING
27
NAFEMS
Introduction – to Althea
• Background in mechanical engineering• PhD applying CFD to an industrial application• First encountered NAFEMS in 1998 and joined the CFD
working group• Elected as chairman of the group in 2002• PSE assessor• Commissioning editor of NAFEMS magazine, Benchmark
NAFEMS
Background• Post-PhD job in industry as the sole analyst, working within the
engineering design department• Short handover from outgoing engineer
– Computer full of simulation files, grouped by project– Verbal description of each project, noted into paper logbook
• Took over existing projects• Asked to provide new results from previous projects
– External drag with simplified external geometry– Downstream flow conditions at domain outlet– Pressure values on curved surfaces where no geometry
surface exists• Frequently moving goalposts during a project
NAFEMS
Two Problems
• Finding previous simulation data
• Understanding what had been done, and why
NAFEMS
Formalised processes• Back in 1998, no-one had heard of SDM • Even PDM systems were relatively uncommon
• As an isolated analyst working in a design department, there were no processes for simulation to inherit
• Part-Solution: set of ‘analysis request’ forms to form the basis of a documented contract between the person requesting the simulation (usually a design engineer) and the simulation engineer (me).
• Different levels of detail depending on the simulation knowledge of the ‘customer’
NAFEMS
Analysis Planning BookAround this time I became involved in the NAFEMS CFD working group and proposed a book on planning a CFD analysis
NAFEMS
Why Plan Simulations?
• Purpose of the simulation• Required output data and locations• Required accuracy • Most suitable models for the physics • Simplifications and assumptions• Simulation quality activities• GIGO
NAFEMS
What happens without a plan?“If you fail to plan, you are planning to fail!”
– Benjamin Franklin
“A goal without a plan is just a wish.” – Antoine de Saint-Exupéry
“Every minute you spend in planning saves 10 minutes in execution”
– Brian Tracy
NAFEMS
Overview of CFD Process
Analysis Request
Request Assessment
Analysis Specification
Geometry Creation
Model Set-up
Solution Process
Solution Verification
Analysis Validation
Post Processing
Report Writing
Data Storage
Non-ConformingAnalyses
Stop if use of CFDis not Justified
Grid Generation
NAFEMS
How to Plan a Simulation 1• Contract with the ‘customer’ and any other stakeholders
– Understand requirements and uses • Physical variables of interest• Agree boundary conditions• Early design assessment or final design confirmation• Subsequent compatibility with other simulations (multi-physics, systems)
– Understand constraints • time available• Accuracy• available input data and quality of that data
– Resource holders• Software and IT suppliers
NAFEMS
How to Plan a Simulation 2
• Consider analysis approach– What assumptions– What models and numerical approach (simulate or not?)– Acceptable convergence
• Consider post processing – Can it be automated– Do surfaces need to be created– How best to communicate the results to the customer
• Record the analysis plan
NAFEMS
What happens if the planning isn’t recorded?
Inappropriate interpretation of simulation resultsInappropriate use of simulation results
Customers and simulation engineers disagree
The wrong simulation might be carried out
NAFEMS
Implementing Analysis Planning
Five levels of metadata management• Scanned paper
– Referencing file names• Electronic Paper
– Pointers to files• Intelligent, modular templates
– Adaptable to particular simulation • Metadata in a database input through/visible in a form
– Pointers to files• Full SDM with Metadata and File management
39
NAFEMS
Comparison of SPDM & Analysis PlanningProject SPDM Analysis PlanningProject Approval Department/Enterprise Team/AnalystSenior Management Attention Essential Not neededSimulation Skill set Team leader with “Process” skills Senior AnalystIT resource Very specialised SDM IT Skills minimalCost €100k to €1M Man‐hours
Value SPDM Analysis Planning
Planning Access to past work Stimulates Thought before Calc.
Reporting Complete, Automated Ensures completeness & rigor
Other ILM, Automation, Global Working, Prepares for SPDM deployment
Management of Complexity, ………
NAFEMS
Audi reported a 35% productivity gain, initially from : – model documentation
– automation of results extraction, 10,000/day – report generation – documentation by creation of 200,000 objects/day
Curve comparison
Report
NAFEMS
Conclusions
• Analysis Planning and Reporting is a valuable technique to improve Governance and Confidence in Results– Brings rigour and traceability to Simulation– Can be deployed quickly with limited effort– Paves the way for an SPDM deployment
• Simulation Data Management has bought complete traceability & instant visibility of complex models, how results were obtained, but implementation can prove a challenge– NAFEMS can help, Body of Knowledge and Training
42
NAFEMS
Q&A
althea@quesadasolutions.co.ukmark.norris@theSDMconsultancy.comsteve.howell@abercus.comprankul.middha@abercus.com
43
NAFEMS
How NAFEMS can help in SPDM
• Confrences– European SPDM Conference 28-29 Novembre 2018 in Munich
• Know-How(BOK) – more than 300 présentations• Books
– Business Value White Paper– Considerations for the Implementation of SPDM (2018)
• WorkingGroup SDMWG – 2nd Thursday of the month Webex• Training
– Introduction to SPDM– Two day Workshop: Essentials of SPDM
NAFEMS
Conclusion: Value & Know-How are Key to SPDM Success
Thank you for your attention
Enterprise’s Needs
Engineer’s Needs
Capabilities of SPDM
SuccessfulDeployment
€ Hours
CAE Data Process
mark.norris@theSDMconsultancy.comyour partner for SDM success
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