In today's world of modern manufacturing if some one is not simulating their processes and products they cannot be competitive. Simulation has several advantages and many people know about it but I have discovered that simulation can have following more advantages.
Having worked for three decades we feel that we have mastered a process or a technology, then we are wrong. Simulation helps clarify those myths that gets ingrained in our system about which we are so convinced. I have personally realized that its the best tool I have to conduct my researches and clarify my several doubts that I had. I feel that the world has lost tons of money because we did not have simulation tools.
You will find that Indian railway bogies have warpage on the external body and they look shabby. These warpages are because of unpredictable distortion of sheet metals due to stresses induced by manufacturing process like welding. There is no expert in the world who can identify the stresses and its effect on a 2 mm sheet. Simulation can exactly show the effect of welding and fixturing which is unimaginable.
I see Indian manufacturers don't have their priorities right. Imagine a slew bearing forging costs 6 lakh rupees and if you loose 5 such forgings you have lost more than the direct cost of a software.
I am not writing this to market a software but i use Simufact currently for forming and I am trying to ratify many of my assumptions and I am convinced that these software's can make a huge difference between being competitive or not.
having done my research in global competitiveness I will always give top priority to technology and use of technology to be competitiveness and if you have to choose between a SUV or a simulation software for your balance sheet depreciation choose a software, or you shall waste money and time taking trials after trials and finally adopting a process which will drain out your revenues for ever.