Simulation in the CPG-retail Industry

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3DS.COM©DassaultSystèmes|ConfidentialInformation|8/2/2018|ref.:3DS_Document_2015
CPG-Retail Segments
PACKAGING SUPPLIERS
Food & Beverage, Tobacco Household Products Beauty & Personal Care
General Retailers Specialty Retail

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Perfect
Production
Perfect
Lab
Perfect
Shelf
Perfect
Product
Perfect
Package
Perfect
Value Chain
Local
Teams
3DEXPERIENCE : Collaborative Innovation
GLOBAL
MARKETS
LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE
Scientists
Formulators
Artwork
Designers
Production
Transportation
Sales
Planning
Stores
Materials
suppliers
Agencies
Management
Local
markets
Digital
Equipment
Suppliers
Packaging
suppliers
LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE
FIRST
MARKET
Packaging
Engineers
Legal

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The New
Consumer
Quickly
Reacting to
Intense
Competition
Profit
Pressures
& Cost
Containment
Imperatives
Regulation
& Need for
Quality
Production
Excellence
Need for
Agile Value
Chain
Health &
Wellness
Constant Challenges of the CPG Industry

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Perfect Package
Design Winning Experiences
Improved Collaboration: Improved between internal stakeholders
and external agencies involved in the Package and Artwork development
process and decision-making
Develop Digital IP : Single version of truth, enable product derivative,
virtual design & visualization, component reuse, accelerate the pace of
package and artwork design review and approval
Cut packaging design time up to 50%. Process simplification
& standardization, streamlined workflows to minimize wait time and waste in
the development process, real time visibility into project status
Reduce packaging material and design costs between
30% to 50%. Detect and correct package errors in the development
process, avoid cost of real mockups, eliminate labeling errors to prevent
product recalls and reducing the product time to market.
Virtually eliminate packaging related recalls. Sustainable
Packaging design, material choice, and increase regulation by enabling
stakeholders in review and approval process

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ZOOM-IN TO THE CPG-RETAIL INDUSTRY
SIMULATION

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Realistic simulations span the entire range of a product's lifecycle
SIMULATION Types
SIMULATION in
CPG-Retail
Transport /
Warehousing
Secondary
Packaging
Stacking
- Palleting
- Topload
Casing
- Wrapping
- Lifting the case
Performance /
Usage
Labelling
Drop Test
- Bottle
- Flexible
- Pack
Squeeze Test
- Bottle - Flexible
Opening / Dispensing
- Flexible - Aerosol
- Can
Sustainability
Lightweighting
Production
Thermoforming
Blow Molding
Capping
Filling
Gas Diffusion &
Pressure
Manufacturing
- Glass - Metal
- Flexible - Carton
Conveying
Retail Context
Ready-to-sell Box /
Shelf Tray
Retail Experience
- Pack Stability on
the Shelf
Product
Product Stability
Product in
Microwave / Oven
Carbon Footprint
Formulation
Optimization
Plastic Injection
Remark: Best so far consolidation, we are still investigating new areas
where SIMULIATION could be important

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3D Simulation WORKS !
Physical Test Virtual Test
Animation courtesy:
Mechanical Design & Analysis Corporation

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Perfect Package for Packaging Design to Transportation Validation
Unique Solution for end to end Packaging on a single Platform
Consumer Unit Design
Customer Unit Design
Automation
Transport Unit Design
Automation
Design Optimization by
Simulation
Packaging Static
Simulation
Transport Dynamic
Simulation

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Challenges Unique to Consumer Goods Simulation
❑ Complexity of materials – far easier to model steel,
aluminum than paper
❑ High to extreme deformation – many problems at
the very edge of what can be achieved with
Lagrangian approach in FEA.
❑ Highly non linear contact.
❑ Complex physics, often requiring a first principles
approach.
❑ Unique automation and deployment challenges

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 Capture Multi-Discipline, Predictive Process (Bottle Example)
 Generate Thousands of Predicted Designs
 Vary multiple Input Parameters
 Compute Simulated Outputs
 Output Parameters linked to downstream models
 Choose the Best Design or Range of Alternates
 Find Best Predicted Design via Ranking Engine
 Quick & Intuitive Design Comparison
 Transparent and Verifiable Decisions
Capacity Pallet Loading CostShelf LifeCrush FEA Analysis
Digital Continuity > Collaborative Trade-Off Analytics Example

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Innovation & Performance Accelerator
SIMULATION Benefit
: Shortlisted design

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MANUFACTURING SIMULATION
BY TYPE OF PACKAGING

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Bottle Design With the 3DEXPERIENCE platform
Blow molding
Simulation
Simulate the manufacturing
process from plug to bottle
to capture entire thickness
distribution
→ Reduce packaging costs
by optimizing material
usage.
→ Reduce design costs by
reducing or eliminating
physical testing.
0

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Simulate the New Pack Design in Real-life Use
Squeeze
Plastic Pack Squeezing

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Filling of the Flexible Package with SIMULIA and Drop Test
Drop test
*Performed with abaqus,
Soon with the 3DEXP

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Predict Stacked Package Weight’s Effect
Palleting / Stacking / Topload
Shampoo Bottle

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Wrapping/ Casing With the 3DEXPERIENCE platform
Wrapping Simulation
Validation of the wrapping
process, measure of
reaction contact.
0

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Reduce damage cost by ensuring that shrink wrap can sustain carrying loads
Casing
Plastic Wrap Lifting the Case

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Transport

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LIGHTWEIGHTING

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Lightweighting
Challenges:
• High raw material costs
• Sustainability & environmental impacts of
the CPG brands
SIMULATION
Values:
• Predict optimal package size for a new
design against fixed constrains
• Reduce raw material use in the
production phase which lead to important
cost reduction over the new product
lifecycle
• Reduce the brand environmental impact

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Initial Design
Simulation Sequence
Max load 100N

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Optimization Sequence
Minimize Mass
Preform Thickness
Max load

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25% Preform Mass Reduction
47% Reduction

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Top Load Thickness Optimization
 Vary thickness smoothly along bottle height
Use 5 thickness values as optimization parameters
 Constraints – minimum TL force > 100 N
 Optimization target – minimize mass

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Top Load Thickness Optimization
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 50 100 150 200 250
Target Thickness
STH

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Analyze Results
Pareto Plots, Interaction Plots

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Preform Thickness

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Optimization Results
 Mass
40.8 → 23.1 – 43% reduction
 Top Loading Force
133 → 103 – reduction
Meets target force
…
Truck
25k bottle:
~445kg
~200,000
Kg resin
saving
250k$
resign
saving
17.8g
saving by
bottle
Lightweighting
Less fuel
CO2= 2.3 kg / L fuel
Packaging
plant:
10M / year

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Reliability analysis using Approximation
DOE Approximation Optimization
Reliability
Studies

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Reliability workflow

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Automated Design Strategies
 Flexible automated design exploration strategies combining DOE, surrogate
models, multi-objective optimization and stochastics.
Y1
Constraint
Boundary
Y2
Initial Design
Search for solution
Optimization
Robust/Reliability Design
(Quality Engineering)
Feasible Infeasible
(safe) (failed)
X2
X1
DOE:
Critical Factors
And Initial Design

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Legacy Applications Vs 3D Experience
CAD
(Catia)
Simulation
Prep
(Abaqus/CAE)
Design
Exploration
(Isight)
Data
management
(SLM)
High performance Computing (Compute Nodes) Abaqus solvers

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Legacy Applications Vs 3D Experience
CAD
(Catia)
Simulation
Prep
(Abaqus/CAE)
Design
Exploration
(Isight/SEE)
Data
management
(SLM)
High performance Computing (Compute Nodes) and Abaqus
Solvers

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3D Experience – One Integrated Platform
3D Experience Platform
(Catia, Exsight, Process Compose, Results Analytics, PLM)
High performance Computing (Compute Nodes) and Abaqus
solvers

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Bottle Design With the 3DEXPERIENCE platform
Bottle Ideation
•Capture the design ideas with CATIA
Application: Natural Sketch
•Define the material properties
Configure the bottle with different sections
•Based on Previous Results, configure
the bottle with some market
information.
•Create and assemble several bottles.
•With the SIMULIA Application
Process composer Optimize the
design of the bottle by changing
parameters Optimize the volume
(Minimize) and the reaction force
(Maximize)
Design Optimization
Management of Parameters
•With CATIA Knowledge
Parameters, we can manage the
parameters of each sections to
adjust the size of the bottle
Validation Simulation
•With the SIMULIA Physical
applications create a top
compression test
•Export Reaction Force
(RF3)
•Blow molding process
Simulation compression
•With the SIMULIA Physical
applications create several
validation simulation (caping,
wrapping)
•Test the consumer usage
with handling tests.
Rendering
•Creation of
realistic
rendering

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CUSTOMERS TESTIMONIES

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Business Challenges Addressed: Lightweighting
Plastic Technologies Case
“Abaqus has become an essential part of PTI’s development process, helping designers address mounting workload
pressures by more quickly screening designs, identifying the best lightweighting opportunities, optimizing the
production process and identifying root-cause failures”
Top-load strength is predicted to drop nearly in half
as container is light-weighted from 17 to 14 grams
with thickness distribution comparison on left
Comparison of actual and simulated Top-load
performance of 14g container

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