Digital Engineering:

Transformation of Product Innovation and

Manufacturing

Engineering Solutions
www.rgbsi.com
Overview
What is digital engineering?

Digital engineering fuses the art of design with the science of data. Integrating data technology with
traditional engineering practices enables highly efficient manufacturing and seamless product innovation.
In addition, applying a strong data foundation to engineering techniques promotes consistency of high
quality product standards.

When most think of digital engineering, a visual of some sort of 3D model comes to mind; however, unlocking
data that exists behind this model is what opens opportunities for true advancement. Digital engineering
encompasses a systematic approach to design, manufacturing, delivery, and maintenance through the
entire lifecycle of a product. With adoption of modern applications, digital information is more accessible
than ever for engineers to drive product innovation, streamline manufacturing, and enhance customer
experiences. Digital engineering connects a continuum of people, process, and technology necessary to
optimize the way products are made. The gradual integration of conventional engineering methods and
technological practices is best known as industry 4.0.

Product innovation must stem from aggregated data to create successful next generation products and
services. Capturing data from user feedback through connected products is replacing traditional survey
methods and driving next generation product improvements. Adoption of digital engineering practices and
technology is a necessity for manufacturers to continuously evolve.

Digital Engineering:
Fuses the art of design with the science of
data by integrating technology with traditional
engineering practices.

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Benefits of Digital Engineering

Increases visibility over engineering processes to improve planning

quality and process control for more informative decision making.

Validates the efficiency of the design, manufacturing, and assembly

process to identify improvement areas and prevent defects.

Ability to align product design with market demand by capitalizing on

user data and analytics.

Creates an environment of systematized communication for all project

stakeholders.

Facilitates collaboration across the supply chain to identify for optimal

efficiency.

Conduct rapid testing and prototyping in virtual environments to deliver

best fit solutions to clients faster.

Evolving Landscape of Digital

Engineering
In today’s modern, high-tech society, people desire constant inclusion and connectivity with their
surroundings. When it comes to customer experiences, personalization plays an instrumental role in how
purchase decisions shape the expectations of business-client relationships. Therefore, consumers are
active participants in the design and development process to ensure new products are compatible with
market demand.

Digital technologies are transforming the way of engineering. This has greatened demand for top talent that
can skillfully digitize processes and products. Intelligent manufacturing offers automated customization,
flexible models, and analytical simulations that deliver personalized manufacturing experiences to
consumers. With the help of new technologies, organizations can connect various enterprise sectors
together to ease collaboration, operability, product traceability, and quality management. This facilitates a
directional flow of information and transparent communication across all stakeholders.

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Digital Disruption
Technology is Transforming Engineering
Manufacturing is a hub for modern technology to progresses product innovation methods. These five
technologies are transforming the look of engineering as we know it.

MBE: AR:
[Model-Based Engineering] [Augmented Reality]
This is used to create a mixed user
The application of computer interpretable
perception by blending a realistic
and data associable visuals that express
environment with computer-generated
design information, particulate a process,
virtual objects that can coexist in the same
or simulate the real behavior of an object.
space.

Digital Thread: AI:

A communication network that enables [Artificial Intelligence]
a connected flow of data as well as an The use of technical systems to perform
integrated view of an asset’s data across tasks that typically require human cognitive
its lifetime through various isolated capabilities to speed up production and
functional perspectives. design generation.

Digital Twin:
A virtual representation of a real physical
object or system that has the capacity to
incorporate data collected through the
physical asset. Use of this technology helps
evaluate product design and performance
hand in hand.

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Model-Based Engineering
Model-based engineering (MBE) uses visuals to express design information, particulate a process, or
simulate the real behavior of an object. Engineers and manufacturing practitioners use models to
communicate definitions and forms of a product. In model-based engineering, models are used in various
domains such as systems, software, electronics, logistics, as well as human behavior. There are two types
of models: descriptive models and computational models.

»» Descriptive models: types of models meant for human consumption and are interpreted by a
human.
»» Computational models: types of models that are machine-readable and are interpreted by a
computer.

Models are important in coming up with an effective practice of exploring, updating, and communicating
aspects of the systems to the stakeholders, while substantially cutting down on additions to traditional
practices. Also, it should be noted that this concept adopts a fundamental assumption that it is paramount
to model and then simulate logically the whole system in order to interpret its behavior.

MBE Establishes a master model which is the basis for all

downstream activities to buildout a product.

Processes

Application of model data drives production and quality processes in manufacturing. These models contain
the data for nominal geometry as well as the additional data required for production. Additional data is
referred to as production manufacturing information (PMI) and it comprises of geometric dimensions and
tolerances, the material and process specs, list of the components, and inspection prerequisites.

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The Digital Thread
The digital thread is defined as a communication network that enables a connected flow of data as well
as an integrated view of an asset across its lifetime through isolated functional perspectives. This concept
promotes transmission of the correct information, to the correct place, at the correct time.

The digital thread is a simple concept of connecting digital information through the product design,
manufacturing, and inspection phases of manufacturing a product. Application of the digital thread lets
manufacturing experts easily view products pass through the manufacturing process in real time to make
the right decisions, operate effectively, as well as maintain product quality. In addition, the digital thread
creates a funnel for data consolidation. Data can be collected from different systems throughout a product’s
lifetime and turned into valuable insight.

The digital thread is important in collaborating product

information across the design, manufacturing, and
inspection phases.

Design

The digital thread has the power to acquire rich benefits across the design phase of a product. Manufacturers
leverage this technology in design to realize tighter iteration loops, greater customization opportunities,
and reduce defect rates. Manufacturers can use development data and field data to refine simple to
sophisticated products. While the digital thread helps consumer goods companies quickly meet market
needs, the actual beneficiaries are manufacturers.

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The Digital Twin
A digital twin is facilitated by the digital thread. It enables manufacturers to understand the workings of a
production run on the shop floor before the actual startup. In this sense, the digital twin plays the role of a
test dummy for engineers and designers to detect any defects and eliminate waste.

The concept entails the digital creation of a product, which encompasses all of its related attributes across
the design, development, manufacturing, and aftermarket phases. This includes aspects such as a product’s
parts list, simulation and analysis results, materials, manufacturing requirements, and quality data. Once
the product goes out to users, data can continuously be collected with the goal of using field performance
to enhance future products. The data collaborated from different engineering technologies, such as CAD,
CAE, and PLM systems, creates synergistic resource sharing on an enterprise scale.

The purpose of the digital twin is to design, develop, and

manufacture a product in a virtual environment.

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Augmented Reality
Use of augmented reality (AR) through multiple phases of the engineering lifecycle allow operational
benefits to be acquired. AR helps engineers visualize products and their interactions before they are
manufactured. This technology is instrumental in the design and development process when aligned with
testing and prototyping strategies.

Design

AR creates a user perception by blending a realistic environment and computer-generated virtual objects
coexisting in the same space. The blended real-virtual environment permits engineers to test concepts early
on in the design process. This technology can dramatically reduce expenses associated with iterations with
early issue detection prior to physical buildout. Enacting a variety of systems and tools in the engineering
process provides greater perspective of product functionality. Design engineers acquire valuable insights
early on by testing virtual product models with real life users.

In addition to design usage, AR has the power to operationalize product development processes and
systems:

»» Provides assembly engineers with instant direction by superimposing work instructions over a
physical work environment.
»» Examines parameters like dimensional accuracy, tolerances, the surface finish, and interference in
quality control processes.
»» Places key procedures in direct view of the technicians operating repairs for machine maintenance.
»» Makes it possible to conduct technical training on a virtual system or part without physical
reassembly and dismantling.

AR visualizes a computer generated design as a final

product in the real world.

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Artificial Intelligence
Artificial intelligence (AI) is a pure opportunity for manufacturers: from maintenance to virtual design, it
enables modern, advanced, and custom products.

Design

AI is a key player in the modern process referred to as a generative design. Within this new process of
manufacturing, engineers input their design objectives including material parameters, manufacturing
processes, and cost constraints into generative design software. The software tests all the probable
alternatives and promptly “generates” all possible design permutations as a solution. Lastly, the software
uses machine learning capability to examine each iteration and determine the best design to adopt.

AI is instrumental in generative design and predictive

maintenance.

Maintenance
Maintenance of machines in manufacturing is one the most frequently performed tasks. AI introduces
a one of a kind method known as predictive maintenance. Unlike preventive maintenance, it eradicates
guesswork as machines are programmed to constantly account their statuses on an up-to-date basis. To
implement predictive maintenance, manufacturing systems are embedded with digital twins, detectors,
and modern analytical tools. It helps save on time and labor costs, as well as ensures optimal manufacturing
performance. For instance, predictive maintenance is used in equipment of manufacturing titanium where
IoT and machine learning are extensively used.

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Conclusion

The digital engineering movement is changing the ways of product innovation and manufacturing. The
integration of industry 4.0 technologies in manufacturing has proven to alleviate expenses, while facilitating
effective process management, data storage, product knowledge, and resource utilization. The future of
manufacturing and many facets of society rely on the evolution of digital engineering.

Digital technologies are transforming the way engineering meets customer requirements. This has created
an upsurge in demand for technical talent with skills to digitize manufacturing processes and product
innovation. Emerging technologies such as model-based engineering, the digital thread, the digital twin,
augmented reality, and artificial intelligence challenge manufacturers to create total value within the context
of customer expectations and production capabilities. Digital engineering presents a unique opportunity
for organizations to generate new methods of effective response to customer needs.

About RGBSI
At RGBSI, we deliver total workforce management, engineering, quality lifecycle management, and IT
solutions that provide strategic partnership for organizations of all sizes. As an organization of engineering
experts, we understand the importance of modernization. Our engineering solutions provide clients with
agility and enhancement through optimizing the value chain to meet industry protocols and full product
specifications.

Have an engineering project? Learn more about our engineering services.

ENGINEERING SERVICES

»» Digital Engineering: digital thread, model-based engineering, robotics & automation, IoT
»» Research: supply chain investigation, FEA, CFD, reverse engineering, competitive benchmarking,
warranty systems
»» Product Design & Development: 2D & 3D modeling, animation, concept sketch proposals, design
automation & customization, embedded systems
»» Support Activities: CAD conversions, work package outsourcing, technical communications &
translations, collaborative manufacturing & testing, CNC & CMM programming, compliance services

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