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A Few (Sometimes Rambling) Thoughts

Intersection of Product Lifecycle Management and Climate Change

Until recently, initiatives to advance sustainability and combat climate change have primarily focused on improving product performance to minimize energy usage and lower greenhouse gas emissions. Product Lifecycle Management (PLM) is enabling technologies and supporting that are contributing to a greener global economy in many ways.

For decades, product development organizations and manufacturers were often forced to choose between product performance and environmental stewardship without regard to externalized costs or long-term harm to the planet.  As a result, sustainability practices were often implemented at the minimum levels required to satisfy regulatory requirements and shareholder expectations.

Today many organizations are taking initiative to an ailing planet. Designing sustainability into a product’s lifecycle offers holistic and integrated solution – and PLM is a critical tool.

Read the complete article in the February issue of Digital Engineering.



Waking up to the Digital World

Think back to last January. The economy was booming, machines were running day and night, 401k’s were soaring, and our biggest concern was finding additional labor. Fewer than 12 months later there are a whole new set of priorities and concerns. We discovered how vulnerable life and business can be, learned to adapt and improvise, and opportunistically embraced new approaches for getting things done.

At home, the kitchen table was transformed to accommodate distance learning for our children. We gave the Internet a workout with online ordering of everything from household supplies and groceries to pizza. And we gained a whole new appreciation for social gatherings with family and friends over the web.

Read the complete article in Plastics Technology Magazine.



Its All About Connectivity

To understand the impact, magnitude, and possibilities of connectivity, one needs to look no further than a piece of technology sitting right there on the desk. Think back a couple short decades ago. What if I had told you that people would one day carry a device – in their pocket mind you – that would instantly connect them to practically anyone in the world or provide on-demand access to any piece of information? Need to reach a friend driving in from Detroit? Just dial. Want to know the average high temperature of Botswana? Just type it in (its 90.9° by the way).

Back then one might have called this a futuristic pipe dream – today its simply known as a smart phone. This hand-held technology connects to massive networks and global search engines at the stroke of a query.

Today’s digital environment provides the foundation for unparalleled automation and connectivity. Organizations like CAVU Group are leveraging this openness to deliver new levels of access, responsiveness, and predictability.

Read more here.



The Changing Landscape of Manufacturing

A Native American proverb teaches that: We do not inherit the earth from our ancestors – we borrow it from our children. Armed with this understanding, organizations across industries and people around the globe are taking an increasingly active role as caretakers of the planet.

Each step toward sustainability – no matter how small – is a good one. And every company – no matter how small – should scrutinize operations to identify and eliminate areas of waste and negligence. For some, such as professional organizations, placing a recycling bin in the cafeteria or reducing paper and water usage might represent the pinnacle of commitment. For larger organizations, a more comprehensive plan is in order.

Because of the nature of their business – along with their impact both at local and globally – manufacturers are often under a microscope to take on a leading role. From examining suppliers to reducing energy usage and emissions, these companies have a unique opportunity (and responsibility) to make a significant and far-reaching impact. But to be truly meaningful, and provide more than incremental results, the undertaking must be planned, managed, tracked, and supported at the highest levels.

As demonstrated throughout its existence, the CAVU Group takes social responsibility very seriously. The company routinely supports local and extended communities through a variety of volunteer and social outreach programs. The company’s commitment toward a sustainable planet is just one more example.

Recently CAVU unveiled and began implementing a corporate strategy designed to advance sustainability by 33%. The process is tracked against an internal scorecard that measures progress throughout the product development and manufacturing process. The initiative, encompassing the entire product lifecycle, focuses on sustainability improvement across three primary segments – environmental, economic, and social.

Product Introduction 

“We have multiple ways of scoring ourselves on sustainability,” explained CAVU’s Marketing Director, Carissa Smith. “From a marketing perspective we do this in the early upstream stages of product planning with steps to determine if the new product is inherently sustainable. Assuming we can validate the sustainability, we craft messaging and create campaigns that clearly communicates this to the world.”

CAVU is also investigating ways to best understand a product’s relationship with the consumer in terms of how it might satisfy sustainability requirements. In this way, next generation products are guided by the voice of sustainable-conscious customers regarding the manner products are designed, developed, used, and disposed of.

Research has shown that younger buyers will actively seek (and in fact are willing to spend a little more on) products that adhere to sustainable practices. Hence, incorporating customer “green” requirements into products and processes is good for the environment, building brand loyalty, and the bottom line.

Product Development

When considering the introduction of a new product, manufacturers must consider the impact of that product on the planet. It’s important to quantify as much as possible to what extent the product will reduce waste and otherwise impact sustainability. Ask questions such as: Can the product be manufactured from recycled material? Is the product itself biodegradable, compostable, or recyclable? How, if at all, will such raw material changes impact quality, manufacturability, or costs?

“We implement best practices to ensure that we’re properly disposing of or reusing manufacturing bi-products and we look at how that product is distributed,” said CAVU Safety & Compliance Officer, Brian Walters. “For example, we examine if the product can be shipped via ground transportation. We look at ways to reduce overnight shipping for our temperature-sensitive products to decrease our carbon footprint. Our goal is to advance sustainability while maintaining the highest quality and service standards.”

Beyond Profits

Environmentally friendly actions don’t have to be large to have an impact. Consistently reducing the amount of energy, water, and paper our businesses use can make a huge difference, both to the environment and to our pocketbooks. How much paper would you save over the course of a year, for instance, if you always ran double-sided copies? How much water is wasted each day by that dripping faucet in the washroom? Small and easy ways to go green – but over time will generate big results!

Organizations, regardless of type, size, or industry are often judged by their commitment to causes greater than the bottom line. Corporate responsibility must reach beyond shareholders, employees, and business goals into the immediate and extended community. For many, this means a tangible, measurable, and on-going commitment toward advancing sustainability. At CAVU Group we are proud to do our part.



Easy Estimates

There’s a lot to like about that fabrication shop that you walk into every day – from the press brake in the corner to the fiber laser you purchased a few years ago. And you have to be excited with the talented new welder you just hired; and don’t forget about that new nesting software that’s going to cut those piles of scrap in half. Now all you need are jobs to run.

“Machines and metal processing services are obviously important,” says Brad Stropes, COO at SecturaSoft. “These things set you apart from competitors. But, as critical as they are, none of them matter without sales. Because of this, most managers take an active hands-on role in sales support, and companies generally assign some of their most tenured employees with estimating responsibilities.”

Read more here.



Building Operator Confidence Through Simulation-Based Training

Albert Einstein once observed that: “Information is not knowledge. The only source of knowledge is experience.” And learning to operate heavy equipment is no different. Vocational schools and construction companies have long recognized that the most effective form of training includes a hefty dose of hands-on instruction. Too often, however, students find themselves at the controls without sufficient seat time under their belt making the jump from the classroom to the cab both intimidating and dangerous. Such an approach can cause students to become frustrated, discouraged, and drop out, which is counterproductive, as it reduces the number of potential operators.

To help close this skills gap, a growing number of vocational schools, training centers, equipment OEMs, and construction companies are incorporating simulators into their training curriculum. Simulation-based instruction allows students to make a smooth transition to equipment training in a virtual, interactive, and controlled environment. Supplementing classroom instruction with simulation builds a foundation for students before being exposed to the complexity and stress of the job site. What’s more, simulators are shown to accelerate learning, advance the student’s success rate, and improve safety – all while lowering training costs.

Read the entire article here



Manitowoc Captures Market Share with Simulation Solutions

When Manitowoc implemented a common control system across its diverse line of cranes, it recognized an opportunity to leverage simulators to support the marketing and sales program behind the initiative, as well as for operator training.

Read the case study here.



Your Approach to Costing Might Be Killing Your Business

This from Plastics Today… Profitability is a delicate balancing act between what it costs to create the product and what the customer is willing to pay. As a plastics processing business owner, you probably have your way of calculating costs. While there is no single, best method, how you choose to implement costing can make or break your bottom line.

Congratulations — your bid won the job! You should be very proud, and maybe even a little worried. On the surface, winning any competitive bid sounds like a boost to your business. But if you’re not adequately covering job-related costs, securing that new business could become a money-losing proposition.

Unfortunately, far too many plastics manufacturing business owners and estimators operate by intuition with no real idea of the best way to account for costs. The good news is there are simple and proven methods that can help quantifiably determine profitability.

Read the story here.



Smart Training Technology: Real-World Operator Experience for Next Gen Equipment Training

Golden, Colorado is home to the Coors Brewery, Lookout Mountain, wild west museums; and, if Terri Olson has anything to say about it, the region’s most effective heavy equipment operator training. As a civil construction business owner, Olson experienced the challenges of hiring, developing, and maintaining a skilled workforce. Driven to advance training through personalized, customer-oriented, instruction she launched Next Gen Equipment Training in the latter stages of 2019.
The company offers a variety of vehicle training options including – hydraulic excavators, wheel and backhoe loaders, heavy construction dozers, motor graders, and articulated trucks. Although classroom and field instruction are provided, there is growing emphasis on simulation-based training.
Retaining qualified operators is a concern for all construction business owners. The key lies not only in competitive wages; but providing opportunity, solid training, and a clear career path. This holds true for seasoned operators as well as young laborers aspiring to take the controls.
Because equipment operators come with a wide variety of experience, skills, and requirements, training centers must have the flexibility to tailor instruction to the needs of each trainee. Attempting this in a field setting is costly, time-consuming, and often weather dependent. For a growing number of equipment trainers, including Next Gen, virtually replicating this environment is the answer.
Next Gen realized that its success could ultimately come down to the simulator they were about to choose. A system would have to represent a true hands-on field experience, adapt to a wide variety of equipment type, usage, and scenarios; and fulfill the unique requirements of students at all levels. With so much on the line, Next Gen began a thorough research of the market.
Read the case study here.


Turbo Charge Innovation by Democratizing Simulation

Suppose that in order to drive a car you were required to be an expert in the dynamics, principles, and physics involved in exactly how a collection of parts interact to propel you down the road?  The overwhelming majority of us would be walking.  While this may appear to be an exaggerated example, one could argue that the manufacturing world has operated in this way for nearly fifty years.

The Advent of CAE

Today’s product development environment employs intelligent Computer-Aided Design (CAD) models to drive new product development.  This is certainly no great revelation; it’s been this way since the 1970s.  About that same time the engineering world began to investigate ways to analyze these models in order to validate parts and sub-assemblies.  The idea was to significantly reduce (or even eliminate) the number of physical prototypes that needed to be built and tested. Time and cost savings associated with validating design early in the product development cycle are staggering.

The importance of this created a need that was quickly filled by engineers who would develop an expertise in the field.  Software tools quickly emerged enabling these experts to put models into motion essentially replicating real-world movement, stress, strains, heat, and failure. The process came to be known as “simulation”.  OEMs throughout such industries as automotive, aerospace, construction and off-highway quickly embraced simulation and continued to invest in the tools and resources to support its use and on-going development.

The ability to apply advanced tools, techniques, expertise, and experience is as much an art as it is a science.  Consequently there remains a relatively small fraternity of CAE experts – many themselves early pioneers, or direct disciples thereof.  These are the custodians of a level of expertise and experience relied upon to perform key analysis.

The dilemma is twofold.  Limited expert resources create unnecessarily long analysis processes that impose time constraints. This reduces the number of design alternative that may be evaluated thereby stifling innovation.  Second, as this generation exits the workforce there is concern that much of their knowledge will retire with them.   The truth is that analysis/simulation is a critical competitive advantage for those who possess it.

What’s New: Simulation Applications

What if there was a way to capture and replicate this expertise?  What if a way existed to embed such tangible knowledge and intangible judgement into a template extending capability throughout the product development team?  The solution lies in Simulation Applications (SimApps), a new application software approach based not on custom programming but rather robust templates which can be easily built and modified.

Solution-specific SimApps are targeted, easy-to-use applications that drive complex simulation templates while speaking the language of the user/engineer.  Project templates are generally set up by your in-house analysis expert as to replicate his/her expertise and your company’s standards.  This service may also be provided by third-parties. Embedding expert knowledge and removing the complexity of general purpose CAE tools, SimApps allow product designers and engineers, without expertise in the use of simulation tools, to safely and quickly evaluate their designs using sophisticated simulations.

A SimApps library allows solutions to be built for virtually any industry or application.  Manufacturers including Intel, American Axle Manufacturing (AAM), GKN, and Magna Cosma, and others are employing SimApps for Drivelines, Gearboxes, Electronics Reliability, and Electro-Optic Sensors to leverage simulation applications to globally enforce expert best practices while measurably increasing the impact of CAE investments on their business.

Extending analysis expertise is essential to innovation.  The faster new designs can be analyzed the more alternatives that can be considered.   It tells us quickly and with confidence which designs to reject and why without the need for expensive and time consuming physical tests.  Yet innovation is unnecessarily held back given the expertise and experience necessary to perform CAE today. SimApps unleash innovation through the insights of a broader group of designers and engineers.

Local Responsiveness & Global Collaboration

Imagine what is possible with quick access information derived from this expert analysis.  Think about how this new level of responsiveness changes the game. Sim Apps deliver the full power of simulation to everyone who needs it, from a salesman who needs to understand the feasibility and cost of a design that meets customer requirements, to a systems engineer who wishes to accurately compare the relative tradeoffs of various architectures, to design engineers who need accurate and rapid assessments of the change in performance of a design variation, to a junior engineer who is still learning the intricacies of CAE codes.

Today, like never before, product development hinges on collaboration.   Leveraging the SimApp approach allows companies to work with disperse departments, suppliers and partners confident that they will maintain control, that standards will be enforced,  consistency will be maintained, and ensuring that the results of the analysis will be valid.

While this may be a difficult cultural shift for many organizations, it delivers tremendous benefits for cost of product development and innovation. As an example, American Axle Manufacturing reports the following major benefits from SimApps for automated NVH analysis of driveline systems.

Empower to Innovate

Simulation has been the exclusive domain of too few for too long. It’s time to put to rest the notion that simulation cannot be safely used unless you have deep expertise in the art of extracting reasonable results from today’s simulation software.  The confluence of simulation methodologies, software, automation templates, and accessible computing hardware, aided by the advent of mobile devices with ubiquitous high-bandwidth access to the Internet, has the potential to magnify the number of users of simulation by an order of magnitude, over the next decade. The results are more innovative products, less engineering rework, and lower product development costs.