Shipulski On Design

Why do factories have 50-ton cranes? Because the parts are heavy and the fully assembled product is heavier.  Why is the Boeing assembly facility so large?  Because 747s are large. Why does a refrigerator plant have a huge room to accumulate a massive number of refrigerators that fail final test?  Because refrigerators are big, because volumes are large, and a high fraction fail final test.  Why do factories look as they do?  Because the design demands it.

Why are parts machined? Because the materials, geometries, tolerances, volumes, and cost requirements demand it.  Why are parts injection molded? Because the materials, geometries, tolerances, volumes, and cost requirements demand it. Why are parts 3D printed? For prototypes, because the design can tolerate the class of materials that can be printed and can withstand the stresses and temperature of the application for a short time, the geometries are printable, and the parts are needed quickly.  For production parts, it’s because the functionality cannot be achieved with a lower-cost process, the geometries cannot be machined or molded, and the customer is willing to pay for the high cost of 3D printing.  Why are parts made as they are?  Because the design demands it.

Why are parts joined with fasteners? It’s because the engineering drawings define the holes in the parts where the fasteners will reside and the fasteners are called out on the Bills Of Material (BOM).  The parts cannot be welded or glued because they’re designed to use fasteners.  And the parts cannot be consolidated because they’re designed as separate parts.  Why are parts held together with fasteners?  Because the design demands it.

If you want to reduce the cost of the factory, change the design so it does not demand the use of 50-ton cranes. If you want to get by with a smaller factory, change the design so it can be built in a smaller factory. If you want to eliminate the need for a large space to store refrigerators that fail final test, change the design so they pass. Yes, these changes are significant. But so are the savings.  Yes, a smaller airplane carries fewer people, but it can also better serve a different set of customer needs.  And, yes, to radically reduce the weight of a product will require new materials and a new design approach.  If you want to reduce the cost of your factory, change the design.

If you want to reduce the cost of the machined parts, change the geometry to reduce cycle time and change to a lower-cost material.  Or, change the design to enable near-net forging with some finish machining.  If you want to reduce the cost of the injection molded parts, change the geometry to reduce cycle time and change the design to use a lower-cost material.  If you want to reduce the cost of the 3D printed parts, change the design to reduce the material content and change the design and use lower-cost material.  (But I think it’s better to improve function to support a higher price.)  If you want to reduce the cost of your parts, change the design to make possible the use of lower-cost processes and materials.

If you want to reduce the material cost of your product, change the design to eliminate parts with Design for Assembly (DFA).  What is the cost of a part that is designed out of the product?  Zero.  Is it possible to wrongly assemble a part that was designed out? No. Can a part that’s designed out be lost or arrive late?  No and no.  What’s the inventory cost of a part that’s been designed out?  Zero.  If you design out the parts is your supply chain more complicated?  No, it’s simpler.  And for those parts that remain use Design for Manufacturing (DFM) to work with your suppliers to reduce the cost of making the parts and preserve your suppliers’ profit margins.

If you want to sell more, change the design so it works better and solves more problems for your customers.  And if you want to make more money, change the design so it costs less to make.

Product simplification can radically improve profits and radically improve product robustness.  Here’s a graph of profit per square foot ($/ft^2) which improved by a factor of seven and warranty cost per unit ($/unit), a measure of product robustness), which improved by a factor of four.  The improvements are measured against the baseline data of the legacy product which was replaced by the simplified product.  Design for Assembly (DFA) was used to simplify the product and Robust Design methods were used to reduce warranty cost per unit.

I will go on record that everyone will notice when profit per square foot increases by a factor of seven.

And I will also go on record that no one will believe you when you predict product simplification will radically improve profit per square foot.

And I will go on record that when warranty cost per unit is radically reduced, customers will notice.  Simply put, the product doesn’t break and your customers love it.

But here’s the rub.  The graph shows data over five years, which is a long time.  And if the product development takes two years, that makes seven long years.  And in today’s world, seven years is at least four too many.  But take another look at the graph.  Profit per square foot doubled in the first two years after launch.  Two years isn’t too long to double profit per square foot.  I don’t know of a faster way,  More strongly, I don’t know of another way to get it done, regardless of the timeline.

I think your company would love to double the profit per square foot of its assembly area.  And I’ve shown you the data that proves it’s possible.  So, what’s in the way of giving it a try?

For the details about the work, here’s a link – Systematic DFMA Deployment, It Could Resurrect US Manufacturing.

Efficient – How do we do more projects with fewer people?

Effective – Let’s choose the right project.

Would you rather do more projects that miss the mark or fewer that excite the customer?

Efficient – How do we finish the project faster?

Effective – Let’s fully staff the project.

Would you rather burn out the project team or deliver on what the customer wants?

Efficient – How do we reduce product cost by 5%?

Effective – Let’s make customers’ lives easier.

Would you rather reduce the cost or delight the customer?

Efficient – How can we go faster?

Effective – Let’s get it right.

Would you rather go fast and break things or get it right for the customer?

Efficient – How many projects can we run in parallel?

Effective – Let’s fully staff the most important projects.

Would you rather get halfway through four projects or complete two?

Efficient – How do we make progress on as many tasks as possible?

Effective – Let’s work on the critical path.

Would you rather work on things that don’t matter or nail the things that do?

Efficient – How can we complete the most tasks?

Effective – Let’s work on the hardest thing first.

Would you rather learn the whole thing won’t work before or after you waste time on the irrelevant?

If there’s a choice between efficiency and effectiveness, I choose effectiveness.

Image credit — Antarctica Bound

At the start, it’s impossible to know the right thing to do, other than the right thing is to start.

If you think you should have started, but have not, the only thing in the way is you.

If you want to start, get out of your own way, and start.

And even if you’re not in the way, there’s no harm in declaring you ARE in the way and starting.

If you’re afraid, be afraid. And start.

If you’re not afraid, don’t be afraid.  And start.

If you can’t choose among the options, all options are equally good.  Choose one, and start.

If you’re worried the first thing won’t work, stop worrying, start starting, and find out.

Before starting, you don’t have to know the second thing to do.  You only have to choose the first thing to do.

The first thing you do will not be perfect, but that’s the only path to the second thing that’s a little less not perfect.

The second thing is defined by the outcome of the first. Start the first to inform the second.

If you don’t have the bandwidth to start a good project, stop a bad one.  Then, start.

If you stop more you can start more.

Starting small is a great way to start.  And if you can’t do that, start smaller.

If you don’t start, you can never finish. That’s why starting is so important.

In the end, starting starts with starting.  This is The Way.

Image credit — Claudio Marinangeli

If you want people to work together, give them a reason.  Tell them why it’s important to the company and their careers.

If you want people to change things, change how they interact.  Eliminate leaders from some, or all, of the meetings.  Demand they set the approach. Give them control over their destiny. Make them accountable to themselves.  Give them what they ask for.

If you want to create a community, let something bad happen.  The right people will step up and the experts will band together around the common cause.  And after they put the train back on the track, they’ll be ready and willing for a larger challenge.

If you want the team to make progress, make it easy for them to make progress.  Stop the lesser projects so they can focus.  Cancel meetings so they can focus. Give them clear guidance so they can focus on the right work.  Give them the tools, time, training, and a teacher.  Ask them how to make their work easier and listen.

If you want the team to finish projects faster, ask them to focus on effectiveness at the expense of efficiency.

If you want the organization to be more flexible, create the causes and conditions for trust-based relationships to develop.  When people work shoulder-to-shoulder on a difficult project trust is created.  And for the remainder of their careers, they will help each other.  They will help each other despite the formal organizational structure.  They will help each other despite their formal commitments.  They will help each other despite the official priorities.

If you want things to change, don’t try to change people.  Move things out of the way so they can make it happen.

Image credit — frank carman

When things don’t go as planned, recognize the Universe doesn’t care about your plan.

When the going gets tough, the Universe is telling you something.  You just don’t know what it’s telling you.

When in doubt, do the next right thing.  That’s how the Universe rolls.

If you don’t like how it’s going, change your situation or change your expectations. Those are the two options sanctioned by the Universe.

If something bad happens, don’t take it personally. The Universe doesn’t know your name.

If you catch yourself taking your plan seriously, don’t. The Universe frowns on seriousness.

Don’t spend time creating a grand plan.  The Universe isn’t big on grand plans.

If your plan requires the tide to stay away, make a different one. The Universe never forgets to tell the tide to come in.

If you find yourself chasing the Idealized Future State, stop.  The Universe has disdain for the ideal.

If something good happens, don’t take it personally. The Universe doesn’t know your name.

When you don’t know the answer, that’s the Universe telling you you may be onto something.

When you have all the right answers, that’s the Universe telling you you’re not asking the right questions.

Image credit — Giuseppe Donatiello

COPYRIGHT GEOFF HENSON

If you’ve done it before, let someone else do it.

If you’ve done it before, teach someone else to do it.

If you’ve done it before, do it in a tenth of the time.

Do it differently just because you can.

Do it backward. That will make you smile.

Do it with your eyes closed.  That will make a statement.

Do its natural extension. That could be fun.

Do the opposite.  Then do its opposite.  You’ll learn more.

Do what they should have asked for. Life is short.

Do what scares them. It’s sure to create new design space.

Do what obsoletes your most profitable offering. Wouldn’t you rather be the one to do it?

Do what scares you.  That’s sure to be the most interesting of all.

Image credit — Geoff Henson

We all have to-do lists. We add things and we check them off.  This list grows and shrinks.  We judge ourselves negatively when we check off fewer than expected and positively when we check off more than that.  But what’s the right number of completed tasks for us to feel good? How many completed tasks is enough?

If you complete one task per week that saves $5000, is that enough? Is it enough to complete fifty tasks per year?  If you create the conditions that make possible a new product line that delivers $1B over three years, but you do that only once every five years, is that enough? Is it enough to do just that one right thing over five years? What does it look like to others when you complete one exceptionally meaningful task every five years? I think it looks like most of the time you are doing very little.

Sometimes you complete small things and sometimes you don’t.  And sometimes you learn what doesn’t work and that’s the completed task.  And sometimes there are long stretches where nothing is accomplished until you create something magical. Counting tasks is no way to go through life.

But counting and measuring is all the rage.  Look at your yearly goals.  Do ten of these.  Run six of those. Complete twelve of the other.  Why do we think we can predict what we should do next year?  Even sillier, do we really believe we know how many of these, those, and the others we will be able to get done next year?  C’mon.  Really?

What if all this counting prevents us from imagining the future? And what if our unhealthy fascination with measuring blocks us from creating it?

If it’s all about the measurable, there’s no room for the Magical.

Why not make some room for the Magical?

Image credit — Philip McErlean

Can you go on holiday and not think about work?

How long does it take your brain to join your body on vacation?

If your boss calls on vacation, what do you do?  And what does that say about you?

If your boss calls on vacation, what does that say about your boss?

Doing something else can help you see things differently when you return from vacation.

Doing nothing is something.

If you can’t let go, might you see your vacation as an opportunity for others to shine?

A new environment can stimulate new thinking.  Why not see your vacation as a new environment?

Hanging around with new people can help you see things differently.  Don’t you meet new people on holiday?

If your company will falter if you’re away for two weeks, it’s time to develop new talent.

If you have access to your email on vacation, are you sure you’re on vacation?

If you look at your email, you blew a whole vacation day.  Switching cost is real.  So is rumination.

You don’t have to be anyone special on vacation.  Why not try that at work?

Vacation isn’t selfish.  It’s healing.

Vacation isn’t time away from work, it’s time immersed in life.

There is no such thing as a halfway vacation.  It’s all-in or it’s not vacation.

Why not go all in?

It’s not possible until you demonstrate it.

It can’t be done until you show it being done.

It won’t work until you make it work.

It must be done using the standard process until you do it a much better way.

It’s required until you violate the requirement and everything is fine.

It’s needed until you show people how to do without.

It’s no one’s responsibility until you take responsibility and do it yourself.

It’s not fun until you have fun doing it.

It’s not sanctioned until you create something magical in an unsanctioned way.

It’s a crappy assignment until you transform it into a meaningful assignment.

It’s a lonely place until you help someone do their work better.

It’s a low-trust place until you trust someone.

It’s scary until you do it anyway.

So do it anyway.

Image credit — Tambako The Jaguar

For right frustration to emerge, you need an accurate understanding of how things are, a desire for them to be different, and a recognition you can’t remedy the situation.

The emergence of your desire for things to be different starts with knowing how things are.  And to see things as they are, you’ve got to be in the right condition – well-rested, unstressed, and sitting in the present moment. When you’re tired, stressed, or sitting in the past or future you can’t pay attention.  And when you don’t pay attention, you miss details or context and see something that isn’t.  Or, if you’re tired or stressed you can have clear eyes and a muddy interpretation. Either way, you’re off to a bad start because your desire for things to be different is wrongly informed. Sure, your misunderstanding can lead to a desire for things to be different, but your desire is founded on the wrong understanding.  If you want your frustration to be right frustration, seeing things as they are is the foundational step.  But it’s not yet a desire for things to be different.

Your desire for things to be different is a subtraction of sorts – when how things are minus how you want them to be equals something other than zero. (See Eq. 1)  Your brain-body uses that delta to create a desire for things to be different.  If how things are is equal to how you want them to be, the difference is zero (no delta) and there is no forcing function for your desire.  In that way, if you always want things to be as they are, there can be no desire for difference and frustration cannot emerge.  But frustration can emerge if you know how you want things to be and you recognize they’re not that way.

Eq. 1   Forcing Function for Desire (FFD) = (how things are) – (how you want them to be)

There is a more complete variant of the above equation where FFD is non-zero (there’s a difference between how things are and how you want them) yet frustration cannot emerge.  It’s called the “I don’t care enough” variant. (See Eq. 2) With this variant, you recognize how things are, you know how you want them to be, but you don’t care enough to be frustrated.

Eq. 2  FFD = [(how things are) – (how you want them to be)] * (Care Factor)

When you don’t care, your Care Factor (CF) = 0.  And when the non-zero delta is multiplied by a CF of zero, FFD is zero.  This means there is no forcing function for desire and frustration cannot emerge.  But this is not a good place to be.  Sure, frustration cannot emerge, but when you don’t care there is no forcing function for change.  Yes, you see things aren’t as you want, but you go along for the ride and don’t do anything about it.  I think that’s sad.  And I think that’s bad for business.  I’d rather have frustration.

Eq. 2 can be used by Human Resources as an Occom’s Razor of sorts.  If someone is frustrated, their CF is non-zero and they care.

Now the third factor required for frustration to emerge – a recognition you can’t do anything about the mismatch between how things are and how you want them. If you don’t recognize you can’t do anything to equalize how things are and how you want them, there can be no frustration.  Think – ignorance is bliss.  If you think you can do something to make how things are the same as how you want them, there is no frustration.  Because it’s important to you (CF is non-zero), you will devote energy to bringing the two sides together and there will be no frustration.  But when there’s a mismatch between how things are and how you want them, you care about making that mismatch go away, and you recognize you can’t do anything to eliminate the mismatch, frustration emerges.

What does all this say about people who display frustration? Do you want people that know how to see things as they are?  Do you want people who can imagine how things can be different?  Do you want people who understand the difference between what they can change and what they cannot? Do you want people who care enough to be frustrated?

Image credit — Atilla Kefeli