Design of Production Processes and Products Using Mathematical Analysis (Simulation)

In manufacturing, actual products and production sites are important, but validation with actual products or at production sites takes time and money. To alleviate these problems, Kao uses different kinds of simulation technologies such as Computational Fluid Dynamics (CFD), heat transfer analysis, structural analysis, or powder and granule simulation to establish more efficient production processes and evaluate product design.

We perform CFD for stirring equipment to evaluate its performance (such as mixing, heat-transfer, and emulsification performance). For example, by simulating droplet breakup, we can see how droplet diameters are changed by scale-up of the equipment or the process conditions. Being able to evaluate the equipment’s emulsification performance via simulations helps us to reduce costs for prototyping with production equipment and the amounts of raw materials used.

For example, by carrying out structural analysis for toothbrushes, we can evaluate how they reach interdental spaces or how different factors affect their brushing performance. Since such simulation allows us to evaluate what influences a change in the brush or tooth shape have without actually prototyping toothbrushes, we can speed up the product development cycle.

As indicated by Moore’s Law, computer performance has been continuing to improve at a rapid pace. We believe that further advances in hardware and more sophisticated algorithms in the future will enable us to perform simulations to levels of accuracy never possible before, or to merge sensor data and physical simulations seamlessly (digital twins). Kao will make the most of simulation technologies and various other digital technologies to realize ideal manufacturing methods that are highly efficient and minimize our environmental impact.