Staying relevant in the automotive industry means introducing products that are ahead of the curve in design, function, performance and reliability. When a progressive domestic automobile manufacturer was faced with testing inefficiencies that jeopardized their premium brand, they turned to DfR Solutions and Sherlock Automated Design Analysis™ software. The result? A testing approach as sleek and innovative as the vehicles produced – and an unanticipated cost savings of over $1 million.
The manufacturer found that the size and weight of powertrains prolonged the duration of required 1,000-cycle power temperature cycling tests (PTC), making physical testing extremely time-consuming and costly.
Time is money in manufacturing. The intended outcome of introducing Sherlock Automated Design Analysis™ software was to automate the powertrain PTC process to:
- Significantly reduce senior engineering time
- Cut reliability testing costs
- Speed time to market
Prior to implementing PTC simulation, the manufacturer ran a series of Sherlock analyses in parallel with the existing test plan to create a baseline comparison of physical versus automated testing. Satisfied with the results, Sherlock was used in powertrain PTC.
Over the course of 12 months, the manufacturer was able to eliminate certain tests within its plan, thereby meeting their desired time and cost efficiencies goals.
Sherlock further proved its value by identifying four designs that fell outside of the manufacturer's acceptable probability of failure range. Since Sherlock alerted them to these shortcomings early in the process, the manufacturer pulled and changed the designs prior to PTC testing – saving themselves nearly $1.4 million in testing that the powertrains otherwise would have failed.
This powerful case study illustrates how Sherlock's unique combination of easy-to-use software and industry-specific Physics of Failure analysis accurately and responsively delivers cost-efficient simulated powertrain PTC testing, timely design revisions, reduced physical testing cycles and faster product introductions to the marketplace.
To learn more about Sherlock and the impact of Physics of Failure on Design for Reliability, download our Introduction to Physics of Failure Reliability Methods webinar slides by clicking the button below.