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Q&A with the CEO: What are the benefits of using Santos®?

This month’s Q&A with Steve Beck, CEO of SantosHuman Inc., addresses the benefits of Santos® to your company.

Q: What are the benefits of using Santos® technologies?

A: Let’s look at this question from 3 different perspectives, all in terms of reducing costs.  We’ll start with the U.S. Government because, frankly, SHI wouldn’t exist without them.  Then we’ll look at Private Industry and finally from the perspective of Safety.

U.S. Government

The original funding for what is now commonly referred to as Santos came from the U.S. Army Tank-Automotive & Armaments Command (TACOM) in 2003.  TACOM program managers explained their motivation for this program in the following way. They told us that the next generation tank would take approximately 13 years to go from white paper to production. Historically, within those 13 years, 9 physical prototypes would be required. Each of those physical prototypes would cost approximately $1B (2003) and 90% of that cost (funded by US Taxpayers) would be committed as soon as the contract to build the prototype was awarded. They also said that one of the critical reasons for creating these physical prototypes was to make sure Warfighter-in-the-Loop issues are understood and addressed prior to production because getting those wrong would cost lives.

Their initial assumption had been that an existing commercial, off-the-shelf (COTS) digital human model (DHM) could be deployed early enough within design cycles to reduce the number of physical prototypes required. This would reduce the cost of, not just next generation tanks, but any new system and allow better designs to be brought into production sooner. However, upon completing a survey of the COTS DHM options available, they determined none of them could be used to achieve this goal. What they said they needed was a way to predict what the Warfighter would do and the program funding, therefore, was a catalyst for DHM research that could lead to capabilities more closely aligned with US DoD DHM requirements.

In the world of Defense Contracting, Santos represents a Warfighter-Centric alternative to the traditional Trial & Error approach to system design that can save billions in taxpayer expenditures.

Private Industry

Many years ago, I had asked our contacts at one of the world’s largest automobile manufacturers what Santos technologies meant to their industry. Based on data from over 100 years of designing and manufacturing automobiles, they said every new vehicle design historically comes with about 5000 problems. Any of those problems that can be addressed prior to production represents a savings of about $50,000. And in the year this conversation took place, they indicated 9 new vehicles would be going into production.

Those numbers suggest $2.25B worth of cost savings if 100% of the issues could be addressed prior to production.  However, they also indicated that not all of those issues are human-centric. Paint, for example, might not cure correctly or hoses may not fit or door assembly mount points may be misaligned. While those are obviously not human-centric issues, they said anywhere between 10% and 20% of those 5000 issues are human-centric.

If you run those numbers and divide by 9 new vehicles, Santos represents savings of between $25M and $50M per new product for one company in a single year because Santos predictive models provide a unique ability to inform and support human-centric design decisions at the earliest stages of product development.

Safety

US companies spend between $50B and $70B per year on work-related injuries. In addition, our contacts within the U.S. DoD have said that the greatest source of lost days for Warfighters is due to equipment use. With that in mind, consider that an extensive study by two World-renowned ergonomists shows that commonly used tools to assess exposure to work-related risk of injury can be off by as much as 16 lbs. This means that even though your company may be assessing tasks for risk of injury, there’s a pretty good chance task risk is being under- or over-estimated.

Manufacturing analysisUnderestimating risk means exposing your workers to increased risk of injury and this is critical for 2 reasons. Not only does it impact the lives of your employees, cost of injury calculators indicate that a single back injury with a $100K payout can have a ripple effect throughout a company requiring an additional $4.2M in sales to offset the cost of just that one injury.

Overestimating risk means expensively and needlessly redesigning tasks that could safely be accomplished as originally designed. Either way, these costs significantly affect the bottom line of just about every company in every industry.  And this is why Santos technologies include the world’s most accurate and most extensively validated method of predicting exposure to risk of injury available today. Use this link if interested in finding out more.

Back to the original question.  What are the benefits of using Santos?  A better question might be, what does it cost to NOT use Santos?

Thanks for tuning in.  You can learn more about other Santos capabilities here and, as always, let us know what you think. We’d love to hear from you.

– S

Video Demo: Integrating Santos into Other Applications

Could a Santos model be added to your product? This video demo shows how the Santos Basic Predictive Model for Physical Behavior, or BPMPB, Software Development Kit (SDK) integrates into existing applications. The Santos BPMPB SDK offers flexibility when integrating into other software environments.

So, if you’re wondering if Santos technology is portable, please watch this video to learn more. It could save your design team even more time during the early stages of product design.

 

Learn more about the Santos BPMPB SDK on our products page.

The Expense of Not Optimizing the HITL: Predictive Models for Precision Grasps

In a previous blog series (post #1 of which can be found here), I had said that traditional design processes do not include human-in-the-loop (HITL) evaluations until so late in a product’s development cycle that change is no longer a realistic option.  While that series focused on just four examples, each from a different industry, SantosHuman Inc. (SHI) works with clients from many industries and the anecdotal evidence for that statement is overwhelming.

Blog series posted.  Next topic.  Moving on.

Or at least, I thought so until a recent client engagement provided an example so perfectly suited to that series that I found myself agitated that it wasn’t included.  This post alleviates that agitation and, going forward, similar posts could serve as addendums to that series.  However, these addendum posts would be used sparingly and only for the most relevant examples because our experience at SHI indicates examples will continue to be plentiful.

Santos precision graspIn this first addendum entry, a global manufacturer in a highly competitive industry redesigned the thumb-operated switchgear on a new product scheduled to be in production soon. They told us their usual approach to evaluating something like this requires a working physical prototype and can take between two and three months to complete. Early on they were notified that a prototype would not be available prior to production so their plan had been to perform the study as soon as the vehicle was in production.  The problem was that the company expected to be producing thousands of these vehicles every day when launched.

Let’s review that last paragraph just in case one of your eyebrows isn’t now several centimeters higher than the other. If the evaluations of the newly designed switchgear were to proceed as originally planned, tens of thousands of their products would be in dealerships and in the hands of new owners by the time the evaluations were complete. As you can imagine, the thought of having to address usability issues for tens of thousands of vehicles, coupled with the loss of market share that accompanies poor operator feedback in a highly competitive market, was causing considerable concern.

Santos thumb switchThey contacted us hoping there might be some way to use just the CAD geometry to perform the switchgear usability evaluations prior to launch.

Once again, we see that traditional and pervasive approaches to product design not only value capability over usability, existing processes make it impossible to even consider usability until it’s too late to do anything about it.

The good news?  As a result of development efforts SHI undertook in 2014 to respond to the needs of one of the world’s largest consumer goods manufacturers (which you can read more about here*), Santos® capabilities include the ability to predict precision and power grasps.  As with all Santos® predictive models, this is a 1st principles approach to predicting grasps that not only affects – and is affected by – the entire body, it can simultaneously take into consideration other competing operator task requirements.

Our clients aren’t interested in replicating what they can already do with the virtual mannequins that have been around for decades.  SantosHuman Inc.’s clients are looking for solutions to problems that would be impossible to solve without us.

Take a look at this unique capability demonstrated in an example use case and then let us know what you think.  We’d love to hear from you.

– S

Q&A with the CEO: What problem is Santos® meant to solve?

This month’s Q&A with Steve Beck, President & CEO of SantosHuman Inc. answers the question of what problems Santos is designed to solve.

Q: What problems are solved by Santos®?

Santos technologies provide a platform that enables our clients to look at humans-in-the-loop in a wide variety of applications. Our capabilities stand out as solutions to not one—but two—of the most persistent problems in product design.

  1. wheelchair analysisDesigning for Humans Earlier in the Process. The Santos first-principles approach to predicting physical human behavior and performance allows human-in-the-loop criteria to be considered at the earliest stages of product development. This enables our defense and private industry clients to design for increased performance and increased customer satisfaction from the start resulting in better designs that can be brought into production sooner. If you haven’t seen the recent blog series on this topic, you can find the first post in that series here.
  2. Predicting Exposure to Risk of Injury. A 12-year study by two world-renown ergonomics researchers involving thousands of subjects indicates that commonly used tools for assessing work-related exposure to risk of injury are not only inaccurate but can be off by as much as 16 lbs. Putting that into perspective relative to the lives of the workers your company employs, assume a task assessment underestimates the load a worker must handle by 16 lbs and your company has been given a green light on that task, which could be as much as 16 lbs. heavier than should be allowed. This means your workers could be performing a task all day, every day, that exposes them to a significant increase in risk of injury. With all of that in mind, consider that a) work-related injuries cost U.S. companies an estimated $50 to $70 billion per year and b) our defense clients have noted that U.S. warfighters lose the most days due to injuries associated with equipment use.lift analysis in Santos Pro

Let’s now assume a task assessment overestimates the load a worker must handle by 16 lbs and your company has been given a red light on that task, which could be performed with minimal exposure to risk of injury as originally designed.  When was the last time you saw a budget line item for unnecessary and expensive task redesign expenditures?

Whether you’re underestimating the loads your workforce can handle and exposing them to increased risk of injury -or- expensively and needlessly redesigning their tasks, relying on commonly and widely used tools for these types of assessments, most of which have been shown to be off by as much as 16 lbs., affects the bottom line of just about every company in every industry.

We worked closely with Professors Jim Potvin, Ph.D., and Nick la Delfa, Ph.D. to provide their solution – the most accurate and extensively validated method of predicting exposure to risk of injury for manual material handling tasks available today – within Santos products through the Arm Force Field Plug-In,

Learn more about other Santos capabilities and, as always, let us know what you think.  We’d love to hear from you.

– S

Video Demo: What’s the Difference Between a Predictive Human Model and a Traditional Digital Human?

As you might expect, I spend a lot of my time talking to people about Santos® technologies.  When they are familiar with digital human modeling at all, they’ll often say things like, “Digital human models have been around for decades.  Our teams have tried them but feel they’re difficult to use and ultimately not that much of a value-add.  Why should we be interested in yours?

For those of us who have been involved from the very beginning in what is now commonly referred to as Santos®, the answer is obvious.  But, simply saying, “Santos provides the ability to predict human physical behavior and performance“, isn’t meaningful before also providing a great deal of additional background information.  This blog post attempts to make one of the many significant values of this unique capability a bit more obvious.

The video linked to below provides a side-by-side comparison highlighting the difference between using a truly predictive human model (on the left) versus the way in which a more traditional digital mannequin is used (on the right).  While Santos® predictive models provide significant advantages for human-centric design and evaluation in any industry, this video focuses on a contrived cab space development application.

How to Watch the Video
Both the left and right sides of the video were created using a single digital human character within our flagship product, Santos Pro.  The right side of the video mimics the traditional way in which digital human models were designed to be used.  The left side demonstrates the use of Santos predictive models.

The right side of the video only needs to be watched once through the first iteration.  There’s a lot happening on the right side of the video at first so it’s not only initially more interesting, it’s almost impossible not to watch.  In comparison, the activities on the left side are rather boring at first as the user is just setting up the constraints required to define an operator task.  So go ahead and focus on the right side through the first iteration.  The activities shown on the left will complete at about the same point in the video as the 1st iteration of the activities on the right so you’re not going to miss anything.  Note, however, that the two sides only complete at about the same time because the right side has been sped up by about 5x and that’s an important point.  It takes less than a minute to set up the predictive model task on the left but takes about 5 minutes for a highly experienced, expert user to manually rotate individual joints into position on the right.

After the first iteration of activities on the right is complete, that clip just repeats over and over until the end.  But you’ll find you don’t have to watch the right side very long to see that manually rotating digital mannequin joints is non-intuitive, time-consuming, and tedious.   In addition, it is clearly a highly subjective process where compromised, even non-human-looking, results are a frequent option.  And as if that wouldn’t be frustrating enough, consider there are no economies of scale to using a digital mannequin.  Every design option explored requires another round of subjective and tedious manual joint rotations.  And then, after all that effort, when you’re all done, what is it you actually know?  It’s no surprise that many design teams consider the use of digital human mannequins an obstacle as opposed to a solution that can be used to bring better, customer-focused designs into production sooner.

In contrast, use of a truly predictive human model (the left side of the video) allows multiple and even competing task objectives to be evaluated in a system-of-systems approach that, in this example, includes seat location, steering wheel and pedal use, and even a vision requirement. The advanced predictive nature of Santos enables your teams to identify Human-in-the-Loop requirements at the earliest stages of product development while change is still a cost-effective option.

SantosHuman Inc.  When getting it wrong is not in the budget.

Take a look and let us know what you think.  We’d love to hear from you.

Santos® Pro provides a foundational platform for truly human-centric design through a full range of predictive human modeling capabilities. Learn more about our complete product line.

Introducing The Santos® Master Class Series on YouTube

If you want to learn more about how to use Santos Pro® or Santos Lite®, our new video series can help. We’ve introduced the first of four Master Class Series videos on our YouTube channel. The first video covers how to predict and simulate task-focused physical human behavior and performance. The second video tutorial shows how Santos Pro avoids collisions and vision obstructions.

Watch the videos here:

Please check back for more videos to be added to this series of tutorials, and contact us if you would like to learn more about Santos Pro® and its capabilities.