Waste Reduction Based

CAE Technology

precision is my friend

hello!
I am
Nugroho Faris Sudrajat, A. Md.,
S.Tr.
You can find me at
Nugrohofaris.sudrajat@mattel.com
precision is my friend

Contents
1.
2.
3.
4.
5.
6.

Introduction
Background
What is CAE ?
What is FEA/FEM ?
Why FEA/FEM ?
CAE/FEA/FEM Application

precision is my friend

1.
Introduction

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Manufacturing

Manufacturing is a branches of
Industry
that
applying
the
equipment
and
media
to
transform a raw material become
a finished/semi-finished good to
be sold

Input :
1. Energy
2. Materials
3. Information

Man

Methods

Machine

Structure
Output :
SQCD

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MATTEL

Mattel is one of manufacturing

industry that processing the
plastic raw material into Finish
Good (Toy).
Safe,
High Quality,
Competitive Price, and
Deliver on time.

Developed

Human Resource
Plant Facilities
Quality of Material
Infrastructure and Work Method system
Information System

the development of science and technology = Globalization

Creativity of product making and processes innovative = Competitiveness

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TION SYSTEM
Requirments
DEVELOPMENT ENGINEERING AND DESIGN

Feed back

Orders

PART AND PRODUCT

DEFINITION DATA

MANUFACTURING PLANNING

MARKETING
& SALES

PROCESS
DEFINITION DATA

PRODUCT
DEMAND
DATA

MANUFACTURING SYSTEM

WASTE
PRODUCTIVITY

MATERIALS

ENERGY

PHYS. CAPITAL

HUMAN LABOR

What, when, how many,

time, how long

Goods

CUSTOMER

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SELLING PRICE DIAGRAM

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1.
2.
3.
4.
5.

Total process
= 4 = 42 =
16 possibility,
The possibility of producing the right product
=
1 possibility,
The possibility of producing the reject product
=
15 possibility,
The ratio of The possibility of producing the reject product = 15/16 = 93.75% Failed,
The ratio of The possibility of producing the right product = 1/16 =
6.25 %

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RIGHT IN
THE FIRST
TIME

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8
CAE (Computer Aided
Engineering
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Background
o
o
o

All the physical phenomena can be

modeled by differential equations
or governing equations.
A differential equation can be
solved by classical analytical
methods or numerical methods.
However, complexities in the
geometry, properties and in the
boundary conditions that are seen
in most real-world problems
usually means that an exact
solution cannot be obtained or
obtained in a reasonable amount
of time.

Current product design cycle

times imply that engineers must
obtain design solutions in a short
amount of time.
They are content to obtain
approximate solutions that can be
readily obtained in a reasonable time
frame, and with reasonable effort. The
CAE is one such approximate solution
technique.
The CAE is a numerical procedure
for obtaining approximate solutions to
many of the problems encountered in
engineering analysis.

precision is my friend

What is CAE ?

Find Weakness
Reduce Wight
Increase Strength
Optimize Performance
Vary Materials
Check Factor of Safety
More..

CAE is the technology

concerned with the use of
computer system to
analysis CAD geometry,
allowing designer to
simulate and study how
the product will behave so
that the design can be
refined and optimized.

Basic Theory of CAE is

FEA/FEM (Finite Element
Analysis/Finite Element
Methods

precision is my friend

o
o

FEA/FEM is one of
numerical methods
to attain approximate
solution of governing
equation by dividing a
large region into small
sub-regions
The sub-regions are
called finite elements
The process of dividing
is called meshing

o Design analysis: hand

calculations, experiments,
and computer simulations
o FEM/FEA is the most widely
applied computer
simulation method in
engineering
o Closely integrated with
CAD/CAM applications

1.
2.
3.
4.

5.

FEA/FEM is a computer
model of a material or
design that can be used in ;
new product design
existing product
refinement
simulating structural
failure
investigating point of
interest not accessible in
reality, e.g., internal
structure
and more

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APPLICATIONS

Mechanical/Aerospace/Civil/
Automobile Engineering
Structure Analysis (Static,
Dynamic, Linear/Non-Linear
Thermal/ Fluid Flows
Electromagnetics
Geomechanics
Biomechanics
More..

precision is my friend

EXAMPLE BY APPLICATION AREAS

AEROSPACE INDUSTRY
- Static Analysis
- Aerodynamics
- Transient dynamics
- Heat transfer
- Fracture Analysis
- Creep & Plasticity Analysis
- Composite Materials
- Aeroelasticity
- Crashworthiness

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EXAMPLE BY APPLICATION AREAS

MOLD MAKING
& PLASTIC PART

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EXAMPLE BY APPLICATION AREAS

MOLD MAKING
& PLASTIC PART

IMBALANCE FILLING IN
BALANCE RUNNER ??????

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Plastic Imbalance Flow Analysis in Channel (Runner) System of

Injection Mold and Balancing Optimization of Runner System
PUBLISHED CODE : LIPI (ISSN 2407-1846)

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Plastic Imbalance Flow Analysis in Channel (Runner) System of

Injection Mold and Balancing Optimization of Runner System
PUBLISHED CODE : LIPI (ISSN 2407-1846)

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EXAMPLE BY APPLICATION AREAS

PLASTIC PART

PRODUCT LIFE TIME

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EXAMPLE BY APPLICATION AREAS

PLASTIC PART

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EXAMPLE BY APPLICATION AREAS

MOLD MAKING
& PLASTIC PART

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EXAMPLE BY APPLICATION AREAS

PLASTIC PART
TOP LOAD

DROP TEST

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EXAMPLE BY APPLICATION AREAS

PLASTIC PART
PULL ANALYSIS

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AVAILABLE SOFTWARE

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IMPACT ?
-

Easier Product Development Process

Product Quality Increase
Improved Life Time Prediction
Improved Service Estimations
Reduction Defect and Fail
Reduction Trial and Error
Productivity Increase
More

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Our process is easy

last

first

first

second
last

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REMINDER

TRASH
TRASH

TRASH

TRASH

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thanks!
Any questions?

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You can find me at

Nugrohofaris.sudrajat@mattel.com

precision is my friend