Shipulski On Design

Archive for the ‘Design Engineers’ Category

Rumor has it, manufacturing is back. Yes, manufacturing jobs are coming back, but they’re coming back in dribbles. (They left in a geyser, so we still have much to do.) What we need is a fire hose of new manufacturing jobs.

Manufacturing jobs are trickling back from low cost countries because companies now realize the promised labor savings are not there and neither is product quality. But a trickle isn’t good enough; we need to turn the tide; we need the Mississippi river.

For flow like that we need a fundamental change. We need labor costs so low our focus becomes good quality; labor costs so low our focus becomes speed to market; labor costs so low our focus becomes speed to customer. But the secret is not labor rate. In fact, the secret isn’t even in the factory.

The secret is a secret because we’ve mistakenly mapped manufacturing solely to making (to factories). We’ve forgotten manufacturing is about designing and making. And that’s the secret: designing – adding product thinking to the mix. Design out the labor.

There are many names for designing and making done together. Most commonly it’s called concurrent engineering. Though seemingly innocuous, taken together, those words have over a thousand meanings layered with even more nuances. (Ask someone for a simple description of concurrent engineering. You’ll see.) It’s time to take a step back and demystify designing and making done together. We can do this with two simple questions:

• What behavior do we want?
• How do we get it?

What’s the behavior we want? We want design engineers to understand what drives cost in the factory (and suppliers’ factories) and design out cost. In short, we want to connect the engineer to the factory.

Great idea. But what if the factory and engineer are separated by geography? How do we get the behavior we want? We need to create a stand-in for the factory, a factory surrogate, and connect the engineer to the surrogate. And that surrogate is cost. (Cost is realized in the factory.) We get the desired behavior when we connect the engineer to cost.

When we make engineering responsible for cost (connect them to cost), they must figure out where the cost is so they can design it out. And when they figure out where the cost is, they’re effectively connected to the factory.

But the engineers don’t need to understand the whole factory (or supply chain), they only need to understand places that create cost (where the cost is.) To understand where cost is, they must look to the baseline product – the one you’re making today. To help them understand supply chain costs, ask for a Pareto chart of cost by part number for purchased parts. (The engineers will use cost to connect to suppliers’ factories.) The new design will focus on the big bars on the left of the Pareto – where the supply chain cost is.

To help them understand your factory’s cost, they must make two more Paretos. The first one is a Pareto of part count by major subassembly. Factory costs are high where the parts are – time to put them together. The second is a Pareto chart of process times. Factory costs are high where the time is – machine capacity, machine operators, and floor space.

To make it stick, use design reviews. At the first design review – where their design approach is defined – ask engineering for the three Paretos for the baseline product. Use the Pareto data to set a cost reduction goal of 50% (It will be easily achieved, but not easily believed.) and part count reduction goal of 50%. (Easily achieved.) Here’s a hint for the design review – their design approach should be strongly shaped by the Paretos.

Going forward, at every design review, ask engineering to present the three Paretos (for the new design) and cost and part count data (for the new design.) Engineering must present the data themselves; otherwise they’ll disconnect themselves from the factory.

To seal the deal, just before full production, engineering should present the go-to-production Paretos, cost, and part count data.

What I’ve described may not be concurrent engineering, but it’s the most profitable activity you’ll ever do. And, as a nice side benefit, you’ll help turn around the economy one company at a time.

Design is typically limited to function – what it does – and is done by engineering (red team).  Manufacturing is all about how to make it and is done by manufacturing (blue team).  Working separately there is local optimization.  We must broad to design to include both – red and blue. Working across red-blue boundaries creates magic.  This magic can only be done by the purple team.

Below is my first video post.  I hope to do more.  Let me know what you think.

When asked how to improve manufacturing, the recipe is clear: lean.  When asked how to improve engineering, the recipe: there isn’t one.  Each engineering improvement effort is unique; though there are common themes and building blocks, each has its own fingerprint.

Each company has its own strengths, weaknesses, opportunities and threats; each company has unique products and markets; each its own goals; each its own culture; each its own future state. Informed by uniqueness, the recipe is unique. To create your unique improvement recipe, I suggest WHY, WHAT, HOW.

WHY
Before your engineering improvement recipe can be formed, the fundamental shaping question must be answered.  Take a breath, fire up your laptop, put on your headphones, and queue up your best music. Type this question:

WHY does our business demand we improve engineering?

Now, type the answer. (Literally.) Use nouns and verbs to explain why engineering must improve. If you can’t, stop. Without a clear, concise, jargon-free answer nothing can be done to advance the cause.  (Though there can be plenty of activity, there can be no progress.) Without the WHY, you cannot pass GO.  You must create a clear, concise WHY.

Seek out help from trustworthy people to create the WHY. Don’t move forward until you understand it well enough to explain it to the engineering organization.  Now, with WHY in place, it’s time for WHAT.

WHAT
Informed by WHY, it’s time for WHAT. Secure a quiet spot, scare up a big piece of paper, and grab your favorite pen. On the top of the page, write this question:

WHAT does engineering improvement look like?

Now, draw the picture. (Literally.) Use sketches, scribbles, arrows, blocks, and people’s names to describe what improved engineering looks like.  Sit in the future and describe it in present tense.  Once drawn, review it with folks you trust, revise it, and repeat.  If you cannot draw the future, keep trying.  Once you have something, review it with folks you trust, revise it, and repeat. Don’t move forward until you draw it clearly enough to explain it to the engineering organization. And with WHAT in place, it’s time for HOW.

HOW
The first step of HOW is similar to WHAT. Pick up your favorite pen, come back to the now, and draw a picture of today’s engineering capabilities, engineering’s current state.  Again, use scribbles, blocks, arrows, and names.

The second step is to define the difference between future and current states.  With future and current state pictures side-by-side, perform a mathematical subtraction: future state – current state.  The difference is HOW. A block in future state that’s not part of the current state is a new thing that must be created; a new arrow in the future state is an activity, interaction, or relationship that must be created; a new person, named or unnamed, represents new thinking. Things that appear in both states are strengths to build on.

The third step, prioritization.  Start here:

What engineering strengths will we build on?

It’s important start with strengths. It sends the right message to the engineering organization: we must build on build on what works, build on what got us here. Engineers need to know that, fundamentally, their work is good, and major building blocks are in place, the foundation is solid.

What development areas will we improve?

Take care with this one.  To avoid a demoralized engineering team, there should be fewer development areas than strengths.  Though there may be many development areas, call out only the most important.

What’s the right first bite?

The most important improvements are those that strongly support the WHY; there’s a natural sequence of things (socks before shoes) that must be respected;  and there’s a finite amount of work that can be done.  Use these three lenses as the start of a prioritization framework.

Building blocks for engineering improvement are the same for all companies: people, tools, and processes, but there are many types of people, countless engineering tools, and all processes can be improved. WHY, WHAT, HOW can help define your unique improvement fingerprint: the right people, the right tools, the right processes, shaped by your unique company goals, and improved in right sequence.

Creating new products that provide a useful function is hard, and insuring they function day-in and day-out is harder.  Plain and simple, engineering is hard.

Planes must fly, cars must steer, and Velcro must stick. But, at every turn, there are risks, reasons why a new design won’t work, and it’s the engineer’s job to make the design insensitive to these risks. (Called reducing signal to noise ratio in some circles.) At a fundamental level engineering is about safety, and at a higher level it’s about sales – no function, no sales.

That’s why at every opportunity engineers reduce risk . (And thank goodness we do.) It makes sense that we’re the ones that think things through to the smallest detail, that can’t move on until we have the answer, that ask odd questions that seem irrelevant. It all makes sense since we’re the ones responsible if the risks become reality. We’re the ones that bear ultimate responsibility for product function and safety, and, thankfully, it shapes us.

But there’s a dark side to this risk reduction mindset – where we block our thinking, where we don’t try something new because  of problems we think we may have, problems we don’t have yet. The cause of this innovation-limiting behavior: problem broadening, where we apply a thick layer of problem over the entirety of a new concept, and declare it unworkable. Truth is, we don’t understand things well enough to make that declaration, but, in a knee-jerk way, we misapply our natural risk reduction mindset. Clearly, problems exist when doing new, but real problems are not broad, real problems are not like peanut butter and jelly spread evenly across the whole sandwich. Real problems are narrow; real problems are localized, like getting a drip of jelly on your new shirt.

How to get the best of both worlds? How to embrace the risk reduction mindset so products are safe and help engineering folks to try something radically new? To innovate?

We’ve got the risk reduction world covered, so it’s all about enhancing the try-something-new side. To do this we need to combat problem broadening; we need a process for problem narrowing. With problem narrowing, engineers drill down until the problem is defined as the interaction of two elements (the jelly and your shirt), defined in space (the front of your shirt) and time (when the knife drops a dollop on your shirt). Where problem broadening tells us to avoid making peanut butter and jelly sandwiches altogether (those sandwiches will always dirty our shirts), problem narrowing tells use to put something between the knife and the front of your shirt, or to put on your new shirt after you make your sandwich, or to do something creative to keep the jelly away from our shirt.

Problems narrow as knowledge deepens. Work through your fears, try something new, and advance your knowledge. Then define your problems narrowly, and solve them.

Innovate.

We all want to increase profits, but sometimes we get caught in the details and miss the big picture:

Profit = (Price – Cost) x Volume.

It’s a simple formula, but it provides a framework to focus on fundamentals. While all parts of the organization contribute to profit in their own way, engineering’s work has a surprisingly broad impact on the equation.

The market sets price, but engineering creates function, and improved function increases the price the market will pay. Design the product to do more, and do it better, and customers will pay more. What’s missing for engineering is an objective measure of what is good to the customer.

To read the complete article, click this link.

Last month a group of engineers met secretly to reinvent the US economy one company at a time.  Here are some of the players, maybe you’ve heard of them:

Alcoa, BAE, Boeing, Bose, Covidien, EMC, GE Medical, GE Transportation, Grundfos, ITT, Medrad, Medtronic, Microsoft, Motorola, Pratt & Whitney, Raytheon, Samsung, Schneider Electric, Siemens, United Technologies, Westinghouse, Whirlpool.

Presenter after presenter the themes were the same: double profits, faster time to market, and better products – the triple crown of product development. Magic in a bottle, and still the best kept secret of the product development community. (No sense sharing the secret sauce when you can have it all for yourself.)

Microsoft used the secret sauce to increase profits of their hardware business by $75 million; Boeing recently elevated the secret methodology to the level of lean. Yet it’s still a secret.

What is this sauce that doubles profits without increasing sales?  (That’s right, doubles.) What is this magic that decreases time to market? That reduces engineering documentation? That reduces design work itself? What is this growth strategy?

When trying to spread it on your company there are some obstacles, but the benefits should be enough to carry the day.  First off, the secret sauce isn’t new, but double the profits should be enough to take a first bite.  Second, its name doesn’t roll off the tongue (there’s no sizzle), but decreased time to market should justify a taste test. Last, design engineering must change its behavior (we don’t like to do that), but improved product functionality should be enough to convince engineering to swallow.

There are also two mapping problems: First, the sauce has been mapped to the wrong organization – instead of engineering it’s mapped to manufacturing, a group that, by definition, cannot do the work. (Only engineering can change the design.) Second, the sauce is mapped to the wrong word – instead of profit it’s mapped to cost.  Engineering is praised for increased profits (higher function generates higher profits) and manufacturing is responsible for cost – those are the rules.

With double profits, reduced time to market, and improved product function, the name shouldn’t matter. But if you must know, its name is Design for Manufacturing and Assembly (DFMA), though I prefer to call it the secret sauce that doubles profits, reduces time to market, and improves product function.

With manufacturing change is easy – lean this, six sigma that, more with less year-on-year. With engineering, not so much. Why?

Manufacturing is about cost, waste, efficiency, and yield (how to make it), and engineering is about function (what it does) – fundamental differences but not the why. The consequence of failure is the why. If manufacturing doesn’t deliver, the product is made like last year (with a bit more waste and cost than planned), but the product still sells. With engineering, not so much. If engineering mistakenly designs the Fris out of the Frisbee or the Hula out of the Hoop, no sales. That’s the why.

No function, no sales, no company, this is fear. This is why it feels dangerous to push on engineering; push on engineering and the wheels may fall off. This why the organization treads lightly; this is why the CEO does not push.

As technical leaders we are the ones who push directly on engineers. We stretch them to create novel technology that creates customer value and drive sales. (If, of course, customers value the technology.) We spend our days in the domain of stress, strain, printed circuit boards, programming languages, thermal models, and egos. As technologists, it’s daunting to push effectively on engineering; as non-technologists even more. How can a CEO do it without the subject matter expertise? The answer is one-page thinking.

One-page thinking forces engineers to describe our work in plain English, simple English, simple language, pictures, images. This cuts clutter and cleans our thinking so non-technologists can understand what’s happening, what’s going on, what we’re thinking, and shape us in the direction of customer, of market, of sales. The result is a hybrid of strong technology, strong technical thinking, and strong product, all with a customer focus, a market focus. A winning combination.

There are several rules to one-page thinking, but start with this one:

Use one page.

As CEO, ask your technical leaders (even the VP or SVP kind) to define each of their product development (or technology) projects on one page, but don’t tell them how. (The struggle creates learning.) When they come back with fifteen PowerPoint slides (a nice reduction from fifty), read just the first one, and send them away. When they come back with five, just read the first. They’ll get the idea. But be patient. To use just one page makes things remarkably clear, but it’s remarkably difficult.

Once the new product (or technology) is defined on one page, it’s time to reduce the fear of pushing on engineering – one-page thinking at the problem level. First, ask the technical leaders for a one-page description of each problem that must be overcome (one page per problem and address only the fundamental problems). Next, for each problem ask for baseline data (test data) on the product you make today. (For each problem they’ll likely have to create a robustness surrogate, a test rig to evaluate product performance.) The problem is solved (and the product will function well) when the new one out-performs the old one. The fear is gone.

When your engineers don’t understand, they can’t explain things on one page.  But when they can, you understand.

I think we can turn around the US economy, one company at a time.  Here’s how:

To start, we must make a couple commitments to ourselves.  1. We will do what it takes to manufacture products in the US because it’s right for the country. 2. We will be more profitable because of it.

Next, we will set up a meeting with our engineering community, and we will tell them about the two commitments. (We will wear earplugs because the cheering will be overwhelming.) Then, we will throw down the gauntlet; we will tell them that, going forward, it’s no longer acceptable to design products as before, that going forward the mantra is: half the cost, half the parts, half the time. Then we will describe the plan.

On the next new product we will define cost, part count, and assembly time goals 50% less that the existing product; we will train the team on DFMA; we will tear apart the existing product and use the toolset; we will learn where the cost is (so we can design it out); we will learn where the parts are (so we can design them out); we will learn where the assembly time is (so we can design it out).

On the next new product we will front load the engineering work; we will spend the needed time to do the up-front thinking; we will analyze; we will examine; we will weigh options; we will understand our designs. This time we will not just talk about the right work, this time we will do it.

On the next new product we will use our design reviews to hold ourselves accountable to the 50% reductions, to the investment in DFMA tools, to the training plan, to the front-loaded engineering work, to our commitment to our profitability and our country.

On the next new product we will celebrate the success of improved product functionality, improved product robustness, a tighter, more predictable supply chain, increased sales, increased profits, and increased US manufacturing jobs.

On the next new product we will do what it takes to manufacture products in the US because it’s the right thing for the country, and we will be more profitable because of it.

If you’d like some help improving the US economy one company at a time, send me an email (mike@shipulski.com), and I’ll help you put a plan together.

a

p.s. I’m holding a half-day workshop on how to implement systematic cost savings through product design on June 13 in Providence RI as part of the International Forum on DFMA — here’s the link. I hope to see you there.

More with more doesn’t cut it anymore, just not good enough.

The behavior we’re looking for can be nicely described by the old TV game show Name That Tune, where two contestants competed to guess the name of a song with the fewest notes. They were read a clue that described a song, and ratcheted down the notes needed to guess it. Here’s the nugget: they challenged themselves to do more with less, they were excited to do more with less, they were rewarded when they did more with less. The smartest, most knowledgeable contestants needed fewer notes. Let me say that again – the best contestants used the fewest notes.

In product design, the number of notes is analogous to part count, but the similarities end there. Those that use the fewest are not considered our best or our most knowledgeable, they’re not rewarded for their work, and our organizations don’t create excitement or a sense of challenge around using the fewest.

For other work, the number of notes is analogous to complexity. Acknowledge those that use the fewest, because their impact ripples through your company, and makes all your work easier.

If you’re reading this you’ve probably survived the great recession. You had to do some radical stuff, but you pulled it off. You cut to the bone as demand fell off, but you managed to shed staff and capacity and kept your company alive. Congratulations. Amazing work. But now the hard part: increased demand!

Customers are ordering, and they want product now. You’re bringing on capacity, re-hiring, and re-training, and taking waste out of your processes with lean and even extending lean to your supply chain and logistics. You’re pulling the levers as hard as you can, but you know it won’t be enough. What you need is another lever, a big, powerful, magical lever to make everything better. You need to pull the product lever.

So, you’re telling me to look at my product as a way to meet increased demand? Yes. To get more products out of few factories? Yes. To make more products with a short staff? Yes. To reduce supply chain complexity? Yes. Pull the product lever, pull it hard, and pull it now.

But meeting increased demand is a manufacturing/supply chain problem, right? No. What about flogging suppliers for unreasonably short lead times? No. What about quickly bringing on unproven suppliers? No. What about bringing on a totally new factory by next week? No. What about using folks of the street to make the product? No. Pull the product lever, pull hard, and pull it now.

Dust off the value stream map of your supply chain and identify the three longest lead times, and design them out of your product. Dust off your routings and identify the three largest labor times, and design them out of our product. Dust off your BOMs and identify the three highest cost parts, and design them out of your product. Pull the product lever. Then, identify the next three, and pull it again. Then repeat. Pull it hard, and pull it now.

Meeting increased demand will be challenging, but your customers and stockholders deserve your best. So, pull hard on all your levers, and pull them now.

What if you could double your factory throughput without adding people?

What if you could reduce your product costs by 50%?

How much money would you make?

How many jobs would you create?

Why aren’t you doing it?

What are you afraid of?