By Mohamed Zairi (Eds.)
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Additional resources for Best Practice. Process Innovation Management
But that is the only area in which the two approaches are in any way similar. In terms of cost, when a single test is considered there is a fivefold benefit in favour of the computer simulation, and when repeat tests are required to develop a design, the computer wins overwhelmingly. Each practical test costs $325,000 (the cost of the vehicle plus the cost of the test), whereas, the costs of a repeated computer simulation are only those associated with any modifications to the model (one to two days, depending on the level of design change) plus the computer costs of the crash calculation, a total of $3,000.
Any new concept taken into a production programme should have been sufficiently well developed in the advanced areas so that the only additional work required would be to ‘tailor’ it to a specific application. A full understanding of customers’ expectation of the product. This will require a translation from customers’ perception of what the product should be capable of achieving - for example ‘good performance’ - to something that the engineer can design towards, in this case, measures of vehicle acceleration, vehicle gearing and weight, and the engine torque curve.
The crashed vehicle is then inspected to establish if it has met various criteria for deformation that relate to the safety of vehicle occupants. If the criteria are not met, the vehicle cannot be released for sale. The practical approach to this is to build and crash a prototype vehicle, to make any design modifications that may be indicated by the test, and then to 22 Best Practice: Process Innovation Management build and crash another prototype. This process being repeated until a successful result is achieved.