Shipulski On Design

Archive for the ‘Engineering Leaders’ Category

Sometimes we engineers know the answer before the question, sometimes we know the question’s wrong before it’s asked, and sometimes we’re just plain pig-headed. And if we band together, there’s no hope of changing how things are done. None. So, how to bring new thinking to the engineering community? In three words: WHAT, WHY, HOW.

WHY – Don’t start with WHAT. If you do, we’ll shut down. You don’t know the answer, we do. And you should let us tell you. Start with WHY. Give us the context, give us the problem, give us the business fundamentals, give us the WHY. Let us ask questions. Let us probe. Let us understand it from all our angles. Don’t bother moving on. You can’t. We need to kick the tires to make sure we understand WHY. (It does not matter if you understand WHY. We need understand it for ourselves, in our framework, so we can come up with a solution.)

WHAT – For God’s sake don’t ask HOW – it’s too soon. If you do, we’ll shut down. You don’t know the answer, we do. And, if you know what’s good for you, you should let us tell you. It’s WHAT time. Share your WHAT, give us your rationale, explain how your WHAT follows logically from your WHY, then let us ask questions. We’ll probe like hell and deconstruct your WHY-WHAT mapping and come up with our own, one that makes sense to us, one that fits our framework. (Don’t worry, off-line we’ll test the validity of our framework, though we won’t tell you we’re doing it.) We’ll tell you when our WHY-WHAT map holds water.

HOW – Don’t ask us WHEN! Why are you in such a hurry to do it wrong?! And for sanity’s sake, don’t share your HOW. You’re out of your element. You’ve got no right. Your HOW is not welcome here. HOW is our domain – exclusively. ASK US HOW. Listen. Ask us to explain our WHAT-HOW mapping. Let us come up with nothing (that’s best). Let us struggle. Probe on our map, push on it, come up with your own, one that fits your framework. Then, and only then, share how your HOW fits (or doesn’t) with ours. Let us compare our mapping with yours. Let us probe, let us question, let us contrast. (You’ve already succeeded because we no longer see ours versus yours, we simply see multiple HOWs for consideration.) We’ll come up with new HOWs, hybrid HOWs, all sorts of HOWs and give you the strengths and weaknesses of each. And if your HOW is best we’ll recommend it, though we won’t see it as yours because, thankfully, it has become ours. And we’ll move heaven and earth to make it happen. Engineering has new thinking.

Whether it’s my favorite new thinking (product simplification) or any other, the WHY, WHAT, HOW process works. It works because it’s respectful of our logic, of our nature. It fits us.

Though not as powerful a real Vulcan mind meld, WHY, WHAT, HOW is strong enough to carry the day.

Some sobering facts: (figure and facts from Matt Slaughter)

• During the Great Recession, US job loss (peak to trough) was 8.4 million payroll jobs were lost (6.1%) and 8.5 million private-sector jobs (7.3%).
• In Sept. 2010 there were 108 million U.S. private-sector payroll jobs, about the same as in March 1999.
• It took 48 months to regain the lost 2.0% of jobs in the 2001 recession. At that rate, the U.S. would again reach 12/07 total payroll jobs around January 2020.

The US has a big problem. And I sure as hell hope we are willing do the hard work and make the hard sacrifices to turn things around.

To me it’s all about jobs.  To create jobs, real jobs, the US has got to become a more affordable place to invent, design, and manufacture products. Certainly modified tax policies will help and so will trade agreements to make it easier for smaller companies to export products. But those will take too long. We need something now.

To start, we need affordability through productivity. But not the traditional making stuff productivity, we need inventing and designing productivity.

Here’s the recipe: Invent technology in-country, design and develop desirable products in-country (products that offer real value, products that do something different, products that folks want to buy), make the products in-country, and sell them outside the country. It’s that straightforward.

To me invention/innovation is all about solving technical problems.  Solving them more productively creates much needed invention/innovation productivity. The result: more affordable invention/innovation.

To me design productivity is all about reducing product complexity through part count reduction. For the same engineering hours, there are few things to design, fewer things to analyze, fewer to transition to manufacturing. The result: more affordable design.

Though important, we can’t wait for new legislation and trade agreements.  To make ourselves  more affordable we need to increase productivity of our invention/innovation and design engines while we work on the longer term stuff.

If you’re an engineering leader who wants more about invention/innovation and or design productivity, send me an email at

mike@shipulski.com

and use the subject line to let me know which you’re interested in. (Your contact information will remain confidential and won’t be shared with anyone.  Ever.)

Together we can turn around the country’s economy.

What is a DFMA Culture?  (.pdf, 1 page)

John Gilligan of Boothroyd Dewhurst, Inc. asked me to describe a DFMA culture.   Here is my description:

At the highest level, a strong DFMA culture is founded on the understanding that The Product strongly governs most everything in a company. Product function governs what customers will pay for; product structure governs a company’s organizational structure; and product features, attributes and materials govern cost. Stepping down one level, the DFMA culture is founded on the understanding that product function and product cost are coupled – they are two sides of the same coin – and are considered together when doing DFMA. Read the rest of this entry »