Case Study: SAE International achieves faster, lower-cost production-ready software testing and robust calibrations with Synopsys Saber virtual manufacturing

SAE International - Customer Case Study

General Motors Propulsion Systems faced costly, time‑consuming development of embedded vehicle software and calibrations that relied on limited prototype testing (SIL/HIL, dyno and vehicle tests). Traditional methods could not economically produce statistically significant sample sizes to capture component variation and aging, contributing to quality, warranty and "no trouble found" issues.

GM partnered with Synopsys to extend its Virtual Manufacturing approach by integrating Saber‑based Monte Carlo subsystem simulation, distributed HPC and a CAL‑SIL software‑in‑the‑loop/calibration workflow. This automated process runs thousands of virtual prototypes, produces production‑ready calibrations (demonstrated on a diesel hydrocarbon injector where CAL‑SIL met GM error bounds while production calibrations did not), identifies hardware issues early, and cuts software testing/calibration costs to a small fraction of traditional estimates while dramatically shortening development time.

SAE International