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October 5, 2005 October 5, 2005 Takehiko Takehiko Kato Kato ( ( tak tak @ @ engineous engineous .com) .com) Engineous Japan, Inc. Engineous Japan, Inc. Realizing Grid Computing as Realizing Grid Computing as Engineering System for Engineering System for Collaborative Parameter Study Collaborative Parameter Study

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Page 1: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

October 5, 2005October 5, 2005

TakehikoTakehiko KatoKato((taktak@@engineousengineous.com).com)Engineous Japan, Inc.Engineous Japan, Inc.

Realizing Grid Computing as Realizing Grid Computing as Engineering System for Engineering System for

Collaborative Parameter StudyCollaborative Parameter Study

Page 2: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Engineous Software, Inc. ?Engineous Software, Inc. ?Engineous Software, Inc. ?

Company established in 1996 spun off from “Engineous Project”of General Electric,

Technology “Software Robot” evolved since 1983 at MIT and GE/CRD

Leading CAO System Supplier (Nearly 300 Customers)

Engineous develops sells and maintains Software Robot SystemiSIGHT for Design Integration/Automation/Optimization/QEM and FIPER for Design Process Collaboration

Headquarter in Cary, North Carolina.

Offices outside of the US– Engineous Japan, Inc. (Japan)– Enginrous Korea, Ltd. (Korea)– Sightna, Inc. (China)– Engineous Software, GmbH(Germany)– Engineous Software Ltd. (UK)– iSIGHT Software SARL (France)

CAO: Computer Aided Optimization/Collaborative Automation and Optimization

Page 3: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Software Robot SystemSoftware Robot SystemSoftware Robot System

Time

OriginalWay

Traditional Improvement(1) Hardware Performance(2) Program Tuning

Data Preparation, Results Analysis, Parameter Change

Traditional Trial&Error Engineering Process

Engineering Process with Software Robot

Applying Software Robot(1) Automation(2) Integration(3) Input/Output Data Management(4) Process Optimization

Software Robot: Parallel Processing

Page 4: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Six Sigma Success Stories at GESix Sigma Success Stories at GESix Sigma Success Stories at GE

Transformer$900K Annual Savings

Nuclear Fuel Reactor$1.2M Cost Savings

Nuclear Satellite Reactor140 Kg Lighter >$14M

DC Motor3 Weeks to 1 Hour

Steam Turbine1 Staff Year to 4 Weeks

Aircraft Engine Turbine10 Weeks to 1 Week

GE90: Saved $250K/Engine

Aero/Mech Blade Design2 Staff Years to 6 Weeks

Power Supply Circuit2 Weeks to 10 Hours

Propeller Design 8 Weeks to 3 Weeks

Halogen Lamps60%Energy Cost Saving

Whiter Light, Brighter ColorLonger Life CycleX10 X10

ImprovementImprovementby

Engineous

Page 5: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Large Scale Parallel Computing in EngineeringLarge Scale Parallel Computing in EngineeringLarge Scale Parallel Computing in Engineering

To be Closer to Physical Phenomenon & Experimental Results– Improving Computational Accuracy by High Fidelity Discrete Modeling

Crash Analysis: 10K Elements (1985) -> 1M Elements (2005)Structure Analysis (NVH): 65K DOF (1990) -> 10M DOF (2005) CFD Analysis : 10M Mesh (1990) -> 1B Mesh (2005)

– Accuracy Improvement, High-Speed, Parallel Processing of Numerical Integration and Matrix Solvers

– Parallel Processing of Discrete Models by Domain Decomposition– More Precise Convergence Scheme with More Number of Iterations

Solving One Large Model with Higher Accuracy in Shorter or Specific Time--- Re-trying Modified Models if Objectives/Targets are not Achieved

Page 6: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Key Subjects in IndustriesKey Subjects in Industries

SPEED: Cycle Reduction in Research/Development/Design/Manufacturing

------ Time to MarketTime to Market

COST: Cost Reduction in Research/Development/Materials/Manufacturing/Resource/Logistics/Maintenance

------ Operation Efficiency, CompetitivenessOperation Efficiency, Competitiveness

QUALITY:Improvement in Quality/Functionality/Performance/Safety

------ Customer Satisfaction, SPEEDCustomer Satisfaction, SPEED、、COSTCOST

Page 7: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Why Design Process Improvement?Why Design Process Improvement?Why Design Process Improvement?

Design andManufacturing

Cost

5%

50%

15%

30%

Influenceon Speed,Cost, Quality

Design

Material

HR

Indirect

5%5%

20%

70%

Leveraging toreduce cost,cycle time,

and time-to-market AND improve quality

Leveraging toreduce cost,cycle time,

and time-to-market AND improve quality

Page 8: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Obstacles in Advanced CAE ProcessObstacles in Advanced CAE ProcessObstacles in Advanced CAE Process

Too Many Design VariablesInfluence of Each Design Variables are UnknownTrade-off Trends between Multiple Responses are UnknownNo Time to Verify Possibility of better Design despite there might beTime is Consumed for Inter-Group adjustment for Target or Design Changes No Match with Experimental ResultsAll the Software and Hardware Resources are Distributed on Global Network

– Multiple Architectures and Operating Systems– Multiple Operational Environments ---Know-how can not be shared– Not Effective Use of All Computing Resources– Many Software Tools are Independently Existing– Very Low Connectivity and Interoperability among the products even from Same

Vendors – Manual based Connection and Execution of Tools– Manual based Communication and Data Exchange

Not Easy to Apply PC-Clusters and UNIX Servers by Efficient MannerGrid Computing?????

Page 9: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Experimental Results & Simulation ResultExperimental Results & Simulation ResultExperimental Results & Simulation Result

SimulationSimulation

ExperimentExperiment

Barrier Model vs. Barrier Force

Page 10: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Experimental Results & Simulation ResultExperimental Results & Simulation ResultExperimental Results & Simulation Result

Simulation Simulation

ExperimentsExperiments

B-Pillar Velocity in Side-Impact

Page 11: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Sources of Variability = UncertaintySources of Variability = UncertaintySources of Variability = Uncertainty

Manufacturing related– Forming processes– Machining processes– Assembly processes

Material related– Material properties– Thickness

Test conditions– Environments– Initial Conditions– Loading Conditions– Boundary Conditions

Human Factors– Beginner or Expeienced– Careless Mistake

Constitutive Models(Governing Equations)

Shape Definition(CAD Representation)

Modeling Techniques(Discretization – FEM, FDM, BEM)

Material ModelsNumerical Algorithms(Integration, Matrix Solving)

Computer Architecture(64bit, 32bit, Numerical Libraries)

Page 12: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Experiments vs. SimulationsExperiments vs. SimulationsExperiments vs. Simulations

Experimental DataPar

amet

er 2

Simulation DataSimulation Data

Data Matching of

Simulation Result to

Experimental Result(s)

Parameter 1

Page 13: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Experiments vs. SimulationsExperiments vs. SimulationsExperiments vs. Simulations

Para

met

er 2

Parameter 1

Experiments

SimulationsSimulations

Stochastic and Statistic Data Matching

between Simulations and Experiments

SimulationsSimulations

Page 14: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 If You have 100 X More Powerful Computers?If You have 100 X More Powerful Computers?If You have 100 X More Powerful Computers?

If you are Scientists/Researchers: Solving 100 Times Higher Fidelity Problems

– Solving Problems which could not be solved before– Chasing Problem Size and Preciseness of Numerical Models

If you are CAE Engineers: Solving 10 Times Higher Fidelity Problems by 10 Iterations

– Improving Accuracy by increasing number of mesh (x 10)– Comparing multiple cases for Improving Design (x 10)

If you are Design Engineers:Solving 100 Cases as Parameter Study

– Statistical Analysis– Trade-off Analysis– Robust Design

Physical Phenomena are all Stochastic! Why not on Computer SimulPhysical Phenomena are all Stochastic! Why not on Computer Simulations?ations?

Page 15: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Parameter Studies by

Parallel Distributed Computing SystemParameter Studies by Parameter Studies by Parallel Distributed Computing SystemParallel Distributed Computing System

PC/EWS

PC/EWS

PC/EWS

PC/EWS

PC/EWS

PC/EWS

PC/EWS

PC/EWS

CPU CPU CPU CPUCPU CPU CPU CPU

Heterogeneous HPC Network (Supercomputers, Servers, Clusters, Grids)

DRM

•Automatic Execution of Tasks•Load Balancing and Resource Management•Automatic Gathering of Computed Results•Automatic Statistic Analysis

CPU CPU CPU CPUCPU CPU CPU CPU

CPU CPU CPU CPUCPU CPU CPU CPU

Parallel Task Parallel Task SubmissionSubmission

Page 16: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Parallel System as Parameter Study EngineParallel System as Parameter Study EngineParallel System as Parameter Study Engine

Effective Use of Large Scale Parallel Processing Systems– Performance Improvement of Single Processor– Limitation in Parallelization, Granularity and Scalability– Bottleneck in Data Transfer between Distributed Memories

Ways to Improve System Efficiency– From Deterministic Simulation to Stochastic/Statistical Simulations– Effective Combination of Parallelism of Single Job and Parallel Parameter

Study– Automatic Data Exploration

Simultaneous Parallel Executions of Multiple Parametric SamplingsCombination of Multiple Sampling and Exploration Methods suitable to Problem Characteristic

Grid Computing – Automatic Data Gathering and Statistic Analysis from Just Job Execution

From Verification of Design by Singe Large Scale Model ExecutionFrom Verification of Design by Singe Large Scale Model Execution

Toward Clarification of Uncertain Elements by Parameter Study Toward Clarification of Uncertain Elements by Parameter Study

Page 17: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Parameter Variation - TerminologyParameter Variation Parameter Variation -- TerminologyTerminology

Random Variable:– Input design parameter that will fluctuate about it nominal, mean value,

perhaps following a probability distributionPure Random Variable – fixed nominal / mean + variationExample: Material Properties (Young’s Modulus, density)Random Design Variable – nominal / mean value is design variable, variation around that nominal / meanExample: Material Thicknesses

Performance Variation:– Fluctuation in performance (output) parameters due to random

variable variation

Design Quality:– Ensuring, to a specific probability, designs will not fail– Reducing, controlling performance variation

Page 18: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Parallel Processing Parameter StudiesParallel Processing Parameter StudiesParallel Processing Parameter Studies

GA(Genetic Algorithm)(1000 Parallel)– All the process in Single Generation

MonteCarlo Method (100 to 10000 Parallel)– Number of Sampling Points

DOE (Design of Experiments) (10 to 1000 Parallel)– Number of Sampling Points based on DOE formulation

Taguchi Method(8 to 1000 Parallel)– Number of Sampling Points based on Orthogonal Arrays

Sensitivity Different Analysis(10 – 1000 Parallel)– Number of Design Variables

Approximation Methods(10 –1000 Parallel)– Sampling Calculations for RSM or Taylor Approximations

Page 19: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Sampling MethodsSampling MethodsSampling Methods

Design Variables

Objectives

Real Solution Space

Sampling Points of Solution SpaceApproximation Model based on Sampling Points

Sampling

for

Approximations

Taguchi Method Sampling

DV1

DV2 Input Output

Computations

MonteCarlo Sampling

Page 20: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Design of ExperimentDesign of ExperimentDesign of Experiment

Define a designed sampling around a baseline design examinedTwo to four factor levels are used typically, though it can havemore levelsEach levels is separated equally (Equal interval) Better for small size sampling, but needs preliminary information about the object system

x1

x2

x3

x1

x2

x3

Three level full factorial design Three level orthogonal design (L9)

Page 21: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Monte Carlo Sampling TechniquesMonte Carlo Sampling TechniquesMonte Carlo Sampling Techniques

Large number of sampling points often requiredUse of “variance reduction technique” can lead to reduced points

Variance Reduction Technique:Descriptive Sampling

Standard MCS:Simple Random Sampling

u-space

fui(ui)

fuj(uj)

uj

uiu-space

fui(ui)

fuj(uj)

uj

ui

Page 22: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Multi-Objective Genetic AlgorithmMultiMulti--Objective Genetic AlgorithmObjective Genetic Algorithm

How to get the Pareto curve – One Approach: Genetic Algorithm

Genetic Algorithm:– Stochastic search algorithm based on evolution mechanism of life(genes)– Multiple search points move solution space independently and simultaneously.– Needs numbers of calculations

Multiple Searching Points

Increase Searching Capability

Increase Calculation Amount

Strength

Weakness

Parallel Efficiency of GA

Overcome

Page 23: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Multi-Objective Genetic AlgorithmMultiMulti--Objective Genetic AlgorithmObjective Genetic Algorithm

MOGA (Multiple Objective Genetic Algorithm)

f1 (x)

f2 (x)

i=0i=ki=k+1

Pareto-optimal solutions

Frontier

Each searching Pont = A Life(gene)

evaluated Life (gene)

More evaluated Life (gene)

Page 24: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Engineering Data Mining

for Multi-Objective AnalysisEngineering Data Mining Engineering Data Mining

for Multifor Multi--Objective AnalysisObjective Analysis

Page 25: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 From Deterministic Simulation

to Stochastic/Statistic SimulationsFrom Deterministic SimulationFrom Deterministic Simulation

to Stochastic/Statistic Simulationsto Stochastic/Statistic Simulations

Y1

ConstraintBoundary

Y2

Initial Design

Search for solutionOptimization

Stochastic/Statistic Solution(Quality Engineering)

Feasible Infeasible (safe) (failed)X2

DOE:Critical Factors

And Initial Design

X1

Page 26: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

From Optimal Design to Robust DesignFrom Optimal Design to Robust DesignFrom Optimal Design to Robust Design

Constraint

Design Variable x

Obj

ectiv

e Fu

nctio

n f(x

)

Function MinimumRobust Solution

∆ f @

∆f @

±∆ x

±∆x

Optimum Mean value for Robust Solution

Infeasible DesignSpace

Feasible DesignSpaceNon-robust :

Weak against randomness

Page 27: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Quality Loss – A Case Study - SONYQuality Loss Quality Loss –– A Case Study A Case Study -- SONYSONY

American consumers consistently preferred overseas setsTVs had identical system design and tolerancesNo out of tolerance sets shipped to any consumer

TargetLower SpecLower SpecLimitLimit

Upper SpecUpper SpecLimitLimit

Freq

uenc

y

SONY SONY JapanJapan

SONY U.S.SONY U.S.US sets built to a flat distribution

QUALITY IS MORE THAN JUST STAYING WITHIN LIMITS

MUST GET CLOSE TO TARGET WHILE MINIMIZING DEVIATION

Page 28: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 QEM ApproachesQEM ApproachesQEM Approaches

MOVEMOVE

Move + ReductionMove + Reduction

Design Variables + Stochastic Variables (Variability depend on Physical Phenomenon)

ReductionReduction

Reliability Optimization:Satisfying Constrain

Robust Design: Minimizing Variance (Taguchi)  

Robust Optimization: Satisfying Constrain & Minimizing Variance (DFSS)

Page 29: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

What is Design for Six Sigma?What is Design for Six Sigma?What is Design for Six Sigma?

Wider MeaningRedesigning of Total Operation Process in order to realize Six Sigma Level Management Quality

Narrower MeaningInnovative Product Design Process in order to realize Six Sigma Level Product Quality

A Structured, Disciplined, Repeatable Process That Will Deliver Near Perfect Products

and Performance

Page 30: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Six Sigma Robust Design - TerminologySix Sigma Robust Design Six Sigma Robust Design -- TerminologyTerminology

Sigma (s):standard deviation of product or process performance - a measure of performance variation

Quality Level / Sigma Level:Can be characterized as percent variation or defects per million:

Sigma Percent Defects Defects per million±σ Variation per million (with 1.5s shift)

1 68.26 317,400 697,7002 95.46 45,400 308,7333 99.73 2,700 66,8034 99.9937 63 6,2005 99.999943 0.57 2336 99.9999998 0.002 3.4

FormerEngineering

Target

NewPhilosophy

Page 31: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Is 99% Near Perfection?Is 99% Near Perfection?Is 99% Near Perfection?

15 Minutes of Unsafe Drinking Water per DayTwo Unsafe Landings per Day at O’Hare20,000 Mailed Letters Lost Each Hour5,000 Incorrect Surgeries Each WeekNo Electricity for Almost 7 Hours Each MonthWatch off by 15 Minutes per Day

Source: controleng.com

Page 32: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Six Sigma – BenchmarksSix Sigma Six Sigma –– BenchmarksBenchmarks

IRS Phone-in Tax Advise 2.2σPrescription Writing 2.9σAverage Company 3.0σAirline Baggage Handling 3.2σBest in Class Companies 5.7σWatch off by 2 Seconds in 31 years 6.0σAirline Industry Fatality Rate 6.2σ

Source: controleng.com

Page 33: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Why Six Sigma Robust Design?Why Six Sigma Robust Design?Why Six Sigma Robust Design?

Cost of Poor Quality– Internal – Scrap, Inspection, Rework, Increased Cycle Time– External – Customer Satisfaction, Warranty, CompetitiveCost: (4σ=25% of Revenue: 6σ=1% of Revenue )

Cost of Change– Apply Six Sigma Early in the Design Phase

Concept

Cost of Design Change ($)

Time

Quality should be “designed, not inspected”Taguchi

Preliminary Detail Manufacture Test Production

Page 34: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 New Viewpoint and Methodology as

Having Infinite Computing ResourceNew Viewpoint and Methodology as New Viewpoint and Methodology as

Having Infinite Computing ResourceHaving Infinite Computing ResourcePast: Assuming Limited Computing Resource

– Requiring to learn from very limited Computational Results– Watching just Specific Trees without Scanning Wider Forest

Computing Environment is Revolutionary Improved !!–– Processor Performance & Multiple Processors (Cluster & Grid CompProcessor Performance & Multiple Processors (Cluster & Grid Computing) uting) –– Memory, Storage Space & Network (Broad Band Network/Internet)Memory, Storage Space & Network (Broad Band Network/Internet)–– Web, PDA, Cellular Phone Web, PDA, Cellular Phone –– Middle Ware (DRM, Web Application Server, DB)Middle Ware (DRM, Web Application Server, DB)

Future:Grid World– Methodology to Execute as Many Calculations as Computing Resource and Time allow– How to draw Effective Information in Max from Many Parametric Studies – Obtaining Essence of Global Phenomena by Data Mining from Mass Computational Results

Engineering Data Mining(Understanding Characteristic of Global Phenomena)– Focusing on Specific Trees after Scanning All Forest

Engineering Data Mining(Scanning All Phenomena)Engineering Visualization(Looking at Specific Phenomenon)Visualization Grid(Deeply Watching One Specific Phenomenon by All)

Page 35: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Theory of Constrains(TOC) and OptimizationTheory of Constrains(TOC) and OptimizationTheory of Constrains(TOC) and Optimization

Summation of Partial(Local) Optima may not be Global OptimumSummation of Partial(Local) Optima may not be Global Optimum→ Partial Optimum may be disturbing Global Optimum ((EliyahuEliyahu M.M. GoldrattGoldratt))→ Troubles will be concentrated on Bottlenecks(Constrains)

Removing BottlenecksRemoving Bottlenecks→ Removing Over/Under Specification and Variances→ Stabilizing Performance/Quality of All Parts and Materials→ Multi-Objective/Multi-Discipline Parameter Study in Components Level→ Multi-Objective/Multi-Discipline Parameter Study in Product Level→ Optimum/Robust Design in Total Product Life Cycle→ Optimum/Robust Process in All Relating Operations

Collaborations in System/Process LevelCollaborations in System/Process Level(R&D → Design → Analysis → Prototyping → Testing → Manufacturing → Supply → Maintenance → Recycling)→ Dependency & Concurrency between Processes (Workflow Control) → Dependency & Communication between Organizations (Horizontal Operation) → Robust Optimization in Global Collaboration

Constructing Global Grid Environment Constructing Global Grid Environment

Page 36: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Turbine Blade DesignTurbine Blade DesignTurbine Blade Design

GAMBIT generates shape-geometry and

mesh.

GAMBIT generates shape-geometry and

mesh.

Mesh fileMesh file

Nastran Bulk data&Pressure ForceNastran Bulk data&Pressure Force

FLUENT calculatesMassFlowRate and

output pressure distribution on dynamic rotor.

FLUENT calculatesMassFlowRate and

output pressure distribution on dynamic rotor.

Nastran calculates VonMisesStress

Nastran calculates VonMisesStress

Design VariablesDesign Variables

VonMisesStressVonMisesStressMassFlow RateMassFlow Rate

Design Variables (circumferential and axial movement blade profile)

– Angle(i)– Xposition(i)– Yposition(i)   [ i=1~4 ]

Objective:– Maximize Mass Flow Rate

Constraints– VonMisesStress.

Tools:– GAMBIT (CAD&Mesh)– Fluent (CFD)– Nastran (FEM)

Page 37: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Turbine Blade Design Automated WorkflowTurbine Blade Design Automated Workflow

MDO Workflow

FEM ResultParametric 

model

3D CAD(GAMBIT)3D CAD(GAMBIT)

Mesh Generator(GAMBIT)

Mesh Generator(GAMBIT) CFD

(FLUENT)CFD

(FLUENT)

judgeinput output

FEM(NASTRAN)

FEM(NASTRAN)

CFD ResultGeometry

Page 38: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Parallel DOE Results(1)ParallelParallel  DOE ResultsDOE Results((11))

View Results Through EDM

better

DOE Post(Pareto plot for Mass Flow Rate)

Page 39: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005

Parallel DOE Results(2)ParallelParallel  DOE ResultsDOE Results((22))

Initial DesignObjective:

– Mass Flow Rate =0.0189 (kg/s)

Constraints– VonMisesStress =16855.54

(Pa)

DOE Best DesignObjective:

– Mass Flow Rate =0.0205(kg/s)

Constraints– VonMisesStress = 17249.03

(Pa)

Parallel DOE+

Grid Computer

Parallel DOE+

Grid Computer

Page 40: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 1D Engine Performance Parameter Study11D Engine Performance Parameter StudyD Engine Performance Parameter Study

Design Variables– Intake Valve Open Timing

  :IVO– Exhaust Valve Open Timing: EVO

– Intake Valve Open Duration:DURi

– Exhaust Valve Open Duration:DURe

Objective FunctionsFuel Economy :BSFCSI

Volumetric Efficiency :VOLEFD

Brake Torque :TORQUE

Page 41: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 1D Engine Performance Parameter Study

(Multi-Objective GA with Engineering Data Mining)11D Engine Performance Parameter Study D Engine Performance Parameter Study (Multi(Multi--Objective GA with Engineering Data Mining)Objective GA with Engineering Data Mining)

Trade-off

20 Populations * 50 Generations=1000 Iterations

Page 42: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Collaboration and Integration:

Top Issues in Executives’ MindsCollaboration and Integration:Collaboration and Integration:Top Issues in ExecutivesTop Issues in Executives’’ MindsMinds

Source: Mercer Consulting Study

Key Customer Pain Points in the PLM Space

Collaboration

Integration

Cost reduction

Reduce TTM

Identify best practices

Optimize resource utilization

Right product and product mix49%

53%

62%

65%

68%

69%

73%

Page 43: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Building, Executing and Managing

Collaborative Engineering ProcessBuilding, Executing and Managing Building, Executing and Managing

Collaborative Engineering ProcessCollaborative Engineering Process

GUI for ComponentsDevelopment

GUI for ComponentsDevelopment

Java Wrapped Java Wrapped ComponentsComponents

GUI for Building WorkflowGUI for Building Workflow

Building Workflow by Building Workflow by Drag and DropDrag and Drop

Building DataflowBuilding Dataflowby Data Mappingby Data Mapping

GUI for System Management

GUI for System Management

System Mgmt. &System Mgmt. &MonitoringMonitoring

GUI for Process ExecutionGUI for Process Execution

Access to LibrariesAccess to Libraries

Distributed Process Distributed Process Environment with Environment with

Efficient IT ResourceEfficient IT Resource

Sharing & Controlling Sharing & Controlling Components as LibrariesComponents as Libraries

Page 44: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Collaborative Parameter Study & Robust DesignCollaborative Parameter Study & Robust DesignCollaborative Parameter Study & Robust Design

Design Study and RealDesign Study and Real--Time Information Exchange byTime Information Exchange bySharing and Integrating Models developed by Multiple OrganizatioSharing and Integrating Models developed by Multiple Organizationsns

HTTPHTTP--XMLXML

Components

Suppliers

Main Contractor

InternetInternet

Components

Suppliers

Sub ModelSub Model

11

Sub ModelSub Model

22

Integrated ModelIntegrated Model

Sub ModelSub Model33

Page 45: Realizing Grid Computing as Engineering System for ... · Sigma (s): standard deviation of product or process performance - a measure of performance variation Quality Level / Sigma

GridWorld/GGF15Boston,2005 Collaborative Parameter Study & Robust DesignCollaborative Parameter Study & Robust DesignCollaborative Parameter Study & Robust Design

MultiMulti--Objective & MultiObjective & Multi--Disciplinary RobustDisciplinary RobustDesign with Process Sharing and Workflow Design with Process Sharing and Workflow ControlControl/Automation/Integration by Inter/Automation/Integration by Inter--Divisions &Divisions &InterInter--EnterprisesEnterprises

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GridWorld/GGF15Boston,2005 Grid Solutions for CollaborationGrid Solutions for CollaborationGrid Solutions for Collaboration

Centralized product development and optimization environment that enables design collaboration with globally dispersed design teams, organizations, and suppliers

Grid

Grid

Grid

Grid

Grid Grid

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GridWorld/GGF15Boston,2005

Parameter Study System as Grid EnablerParameter Study System as Grid EnablerParameter Study System as Grid Enabler

Current Status of Grid– Many Middleware such as Globus, LSF, Grid Engine, PBS-Pro– Considering Mainly Job Dispatching but not Computational Results– Parallel Processing of Very Large Scale Simulation (Parallel Efficiency?)– Trying to Deliver Single Deterministic Optimum through Parameter Studies – Usage of Computer Resource is increased, but how about Design Efficiency?

Realizing More Practical Grid– Applying Middleware as Distributed Resource Management (DRM) – Automatically Generating Multiple Parameter Combination and Input Data– Automatically and Concurrently Executing Multiple Simulations in Parallel Distributed

Environment – Statistically Analyzing Computational Results in Automatic Manner

Trade-off Analysis and Approximation of Design Space – Automatically Executing the follow-on Simulations by applying Previous Results– Not only Improving Computing Resource Usage but also Design Efficiency– Global Grid for Collaborative Parameter Study/Knowledge Base System for Robust Design

The Importance isto Statistically Analyze the Results

to Store as Knowledge Base and to Apply for the future