Find where the design behaves differently
Compare simulation with physical tests under matching loads, conditions and configurations
Understand what a revision changes
Examine design alternatives against performance requirements and test results before choosing a revision
Give a failure warning a physical basis
Evaluate potential failure risk using load histories, sensor readings and inspections
Investigate the fault in its system context
Bring component histories, anomalies and test conditions together to examine possible root causes
Define what a better outcome looks like
Which design assumptions stop holding under real operating conditions?
- Start with a fair comparison
- Choose a configuration and test regime, with acceptance criteria and a comparison baseline agreed by the engineering team
- Keep the decision in view
- Inspect discrepancies against loads and component histories, then record the design, model or inspection change chosen
- Measure the result
- Track prediction error, test failures and discrepancies that persist after revisions. Review rework hours and repeated failures against the changes made