Shipulski On Design

The best way I know to help the engineers to believe it’s possible to design out half the parts is to help them what’s in the existing product.  To do that, help them go through the BOM of the existing product part by part.  Categorize each part as: fastener, connector, protector, label/sticker, and main part, and total up each category.  The engineers learn that there are a few main parts and a boatload of fasteners, connectors, protectors, and stickers.  After they see the totals, they believe it’s possible to design out half the parts.

The next step is to create a design approach. Using the BOM, create a Pareto chart of part count by subassenbly and the design approach is clear – focus on the subassemblies with the most parts.

When the design engineers know the types of parts and the amount of each within each subassembly, the design approach is clear, and the work can begin.

And if you want to turn it up to eleven, train them on Boothroyd Dewhurst’s  DFMA tools and help them use them.

Here’s the recipe: use the BOM to create Pareto charts of part count by part type and part count by subassembly; create a design approach and redesign the subassemblies with the most parts.  And for unbelievable results, train the team on BDI’s DFMA toolset and help them use it on the subassemblies with the highest part count.

It’s a straightforward process, but it’s challenging in an emotional sense. You’ve got to help the engineers believe it’s possible to design out half the parts.  It’s not easy to obsolete your best work.

Help them believe, and you’re on your way.  Here’s a post on how to help the company see the design community as the Heroes of the Company.

Image credit — Hartwig HKG

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