CLIENT PROFILE
Our client is a major OEM in the automotive sector specializing in full-vehicle development. One of their key competencies is the design and manufacturing of high-performance gearboxes that meet today’s increasingly demanding performance, sustainability, and cost-efficiency requirements.
THE CHALLENGE
With increased pressure on time-to-market and reduced CO₂ emissions, our client sought to cut reliance on costly physical prototypes and improve design confidence through system-level simulation.
To add complexity, a change in simulation software had been made internally — requiring revalidation and benchmarking of all existing models against older results or physical tests. As Simon, our consultant, recalls:
“Both software packages were capable enough, but switching was essential to streamline with our international colleagues. That meant we had to re-establish correlation and rebuild trust in the models from scratch.”
Additionally, the company was planning to switch to a new supplier for a critical component set — a move that could save millions per year. However, the supplier lacked simulation capabilities, creating an urgent need for internal validation to avoid delays and support the business case.
OUR SOLUTION
Initially onboarded as a test engineer, Simon quickly demonstrated strong capabilities and transitioned to a Simulation Engineer role through Engibex. His task: establish confidence in a new simulation methodology using CFD, while supporting urgent design validation for the gearbox system.
“The goal was clear: validate the methodology so that future models could be trusted. We needed to show that simulation results weren’t just numbers, but reliable predictions.”
Working both independently and with cross-domain colleagues (FEA, NVH, 1D simulation), Simon led the correlation process between old and new simulation software, helped reduce simulation cycle times, and spearheaded direct collaboration with suppliers to align models.
Beyond technical delivery, he also ensured rapid information gathering through a proactive approach — calling suppliers regularly, pushing past standard delays, and maintaining close collaboration with international engineering teams involved in the simulation process.
IMPACT & OUTCOME
Thanks to a validated simulation model, our client was able to:
- Replace €80,000 worth of physical tests with virtual validation in 2024 alone.
- Move forward with a new component supplier, generating monthly savings of approx. €500,000.
- Gain trust in CFD results and cut reliance on slow, expensive prototyping.
- Strengthen cross-functional collaboration across global teams.
WHY ENGIBEX
This case shows the agility and people-first mindset at the core of how Engibex operates. When Simon expressed interest in switching roles, the first steps of the transition were made within a week, and the complete move to simulation was completed within three months.
“I felt supported from the very beginning. Engibex didn’t just place me in a project — they enabled me to grow into a role where I could make a bigger impact.”
From test benches to high-impact simulations, this story highlights how combining talent, autonomy, and speed can deliver real engineering value.
