Uploaded February 2023 | Updated September 2026, 2 weeks ago
Cummins explains how optimization supports its analysis-led design initiative for faster, higher-quality product development. The video describes how engineering teams are moving from component-level optimization toward subsystem and system-level trade-offs for engines and power generation units. The outcome is a more integrated simulation workflow that helps Cummins pursue first-time-right designs, balance customer requirements, and improve interoperability across engineering tools.
*Engineering domain:*
Engine development, power generation systems, mechanical engineering, modeling and simulation, analysis-led design, system-level optimization, and digital engineering.
*Type of problem:*
Cummins wants to get products right the first time, develop them faster, and deliver higher quality to customers. To do this, the company needs to optimize not only individual components, but also the way components work together inside larger subsystems and full systems.
*Tools and solvers involved:*
- modeFRONTIER
- CAD models
- CFD workflows
- Structural analysis workflows
- Thermal analysis workflows
- Modal analysis workflows
- Mesh morphing
- High performance computing grids
- ANSYS core software
- Simulation interoperability workflows
- Engineering scripts for software integration
*Key concepts covered:*
- Analysis-led design
- Cummins
- modeFRONTIER
- First-time-right design
- Product quality
- Faster product development
- Cross-functional engineering
- Component optimization
- Subsystem optimization
- System-level optimization
- Engine optimization
- Power generation systems
- Trade-off analysis
- Total cost of ownership
- Initial cost
- Fuel economy
- Emissions
- CAD-driven modeling
- CFD
- Structural analysis
- Thermal analysis
- Modal analysis
- Mesh morphing
- High performance computing
- ANSYS
- Software interoperability
- Simulation automation
- Customer requirements
*Chapters:*
0:00 – Introduction to analysis-led design at Cummins
0:07 – Why did Cummins start the analysis-led design initiative?
0:21 – What cross-functional challenges affect product development?
0:28 – Reformulating technical functional excellence groups
0:40 – How teams align around customer product requirements
0:56 – How has Cummins used optimization in the past?
1:01 – Moving from component optimization to subsystem and system optimization
1:14 – Why optimized components may not create the best system
1:22 – How trade-offs help connect components into larger systems
1:29 – Keeping component reliability as the first priority
1:37 – Optimizing weight, cost, and customer value
1:45 – Combining components into engines and power generation units
1:55 – Why the whole system may require sub-optimal components
2:07 – Customer priorities: cost, quality, fuel economy, and emissions
2:24 – How Cummins drives models from a common CAD source
2:34 – Why different physics require different meshed models
2:42 – Combining CFD, structural, thermal, and modal analysis
2:54 – How mesh morphing and geometry changes connect back to CAD
3:03 – Using modeFRONTIER to optimize across parameters and constraints
3:20 – Why interoperability remains a key engineering challenge
3:27 – How high performance computing supports larger simulations
3:34 – Cummins’ ANSYS software agreement and global simulation use
3:45 – Growing HPC grid capability and simulation capacity
3:57 – Why software interoperability will continue to matter
4:15 – Why end users still spend time connecting simulation codes
4:28 – How standardizing interoperability can help engineering teams
*Related ESTECO resources:*
- modeFRONTIER product page: engineering.esteco.com/modefrontier
- Design optimization technology: engineering.esteco.com/technology/design-optimization
- Simulation process integration and automation: engineering.esteco.com/technology/simulation-process-integration-automation
- Robust design and reliability: engineering.esteco.com/technology/robust-design-and-reliability
- HPC and cloud: engineering.esteco.com/technology/high-performance-computing-cloud
- Simulation data analytics: engineering.esteco.com/technology/simulation-data-analytics
#AnalysisLedDesign #modeFRONTIER #Cummins #SystemOptimization
Cummins explains how optimization supports its analysis-led design initiative for faster, higher-quality product development. The video describes how engineering teams are moving from component-level optimization toward subsystem and system-level trade-offs for engines and power generation units. The outcome is a more integrated simulation workflow that helps Cummins pursue first-time-right designs, balance customer requirements, and improve interoperability across engineering tools.
*Engineering domain:*
Engine development, power generation systems, mechanical engineering, modeling and simulation, analysis-led design, system-level optimization, and digital engineering.
*Type of problem:*
Cummins wants to get products right the first time, develop them faster, and deliver higher quality to customers. To do this, the company needs to optimize not only individual components, but also the way components work together inside larger subsystems and full systems.
*Tools and solvers involved:*
- modeFRONTIER
- CAD models
- CFD workflows
- Structural analysis workflows
- Thermal analysis workflows
- Modal analysis workflows
- Mesh morphing
- High performance computing grids
- ANSYS core software
- Simulation interoperability workflows
- Engineering scripts for software integration
*Key concepts covered:*
- Analysis-led design
- Cummins
- modeFRONTIER
- First-time-right design
- Product quality
- Faster product development
- Cross-functional engineering
- Component optimization
- Subsystem optimization
- System-level optimization
- Engine optimization
- Power generation systems
- Trade-off analysis
- Total cost of ownership
- Initial cost
- Fuel economy
- Emissions
- CAD-driven modeling
- CFD
- Structural analysis
- Thermal analysis
- Modal analysis
- Mesh morphing
- High performance computing
- ANSYS
- Software interoperability
- Simulation automation
- Customer requirements
*Chapters:*
0:00 – Introduction to analysis-led design at Cummins
0:07 – Why did Cummins start the analysis-led design initiative?
0:21 – What cross-functional challenges affect product development?
0:28 – Reformulating technical functional excellence groups
0:40 – How teams align around customer product requirements
0:56 – How has Cummins used optimization in the past?
1:01 – Moving from component optimization to subsystem and system optimization
1:14 – Why optimized components may not create the best system
1:22 – How trade-offs help connect components into larger systems
1:29 – Keeping component reliability as the first priority
1:37 – Optimizing weight, cost, and customer value
1:45 – Combining components into engines and power generation units
1:55 – Why the whole system may require sub-optimal components
2:07 – Customer priorities: cost, quality, fuel economy, and emissions
2:24 – How Cummins drives models from a common CAD source
2:34 – Why different physics require different meshed models
2:42 – Combining CFD, structural, thermal, and modal analysis
2:54 – How mesh morphing and geometry changes connect back to CAD
3:03 – Using modeFRONTIER to optimize across parameters and constraints
3:20 – Why interoperability remains a key engineering challenge
3:27 – How high performance computing supports larger simulations
3:34 – Cummins’ ANSYS software agreement and global simulation use
3:45 – Growing HPC grid capability and simulation capacity
3:57 – Why software interoperability will continue to matter
4:15 – Why end users still spend time connecting simulation codes
4:28 – How standardizing interoperability can help engineering teams
*Related ESTECO resources:*
- modeFRONTIER product page: engineering.esteco.com/modefrontier
- Design optimization technology: engineering.esteco.com/technology/design-optimization
- Simulation process integration and automation: engineering.esteco.com/technology/simulation-process-integration-automation
- Robust design and reliability: engineering.esteco.com/technology/robust-design-and-reliability
- HPC and cloud: engineering.esteco.com/technology/high-performance-computing-cloud
- Simulation data analytics: engineering.esteco.com/technology/simulation-data-analytics
#AnalysisLedDesign #modeFRONTIER #Cummins #SystemOptimization
