Shipulski On Design

Posts Tagged ‘Engineering Mindset’

Meeting agendas are a good idea. They make clear what will happen and they’re time bound. (At least good ones.) They look forward in time and shape what will happen.

Meeting agendas are created by the organizer so others follow. It’s strange to think about, but from thin air, the organizer congers magic words on a page that shape direction. The agenda sets the agenda and it’s followed. But in truth, agendas are followed because we choose to follow.

But I want to introduce another schema – the work sets the agenda. In this parallel universe, we don’t choose to follow an agenda; we choose to do work so powerful it sets the agenda – work so dense its gravitational field pulls the organization toward it.

I can hear the moans and groans – we can’t choose the work we do. But you can – if your work is good enough. If your work is brighter than the sun, it’s undeniable and, like the sun, cannot be ignored.

I can hear the next round of moans – we can’t do work that good. But you can – if you think you can and you try. (The only way to guarantee you can’t is not to try.)

And the last round of groans – we’ll get fired if we fail. If you’ll get fired for trying to reinvent your universe, you’re working at the wrong place anyway.

If you like to follow agendas, follow them. But if you don’t, do celestial work, and set them.

The more work I do with innovation, the more I believe mindset is the most important thing.  Here’s what I believe:

Doing new doesn’t take a lot of time; it’s getting your mind ready that takes time.

Engineers must get over their fear of doing new.

Without a problem there can be no newness.

Problem definition is the most important part of problem solving.

If you believe it can work or it can’t, you’re right.

Activity is different from progress.

Thinking is progress.

In short, I believe state-of-the-art is limited by state-of-mind.

Engineers hate uncertainty. (More precisely, it scares us to death.) And our role in the company is to snuff it out at every turn, or so we think.

To shield ourselves from uncertainty, we take refuge in our analyses. We create intricate computer wizardry to calm our soles. We tell ourselves our analytic powers can stand toe-to-toe with uncertainty. Though too afraid to admit, at the deepest level we know the magic of our analytics can’t dispatch uncertainty. Like He-Who-Should-Not-Should-Be-Named, uncertainty is ever-present and all-powerful. And he last thing we want is to call it by name.

Our best feint is to kill uncertainty before it festers. As soon as uncertainty is birthed, we try slay it with our guttural chant “It won’t work, it won’t work, it won’t work”. Like Dementors, we drain peace, hope, and happiness out of the air around a new idea. We suck out every good feeling and reduce it to something like itself, but soulless. We feed on it until we’re left with nothing but the worst of the idea.¹

Insidiously, we conjure premonitions of mythical problems and predict off-axis maladies. And then we cast hexes on innovators when they don’t have answers to our irrelevant quandaries.

But our unnatural bias against uncertainty is misplaced. Without uncertainty there is no learning. Luckily, there are contrivances to battle the dark art of uncertainty.

When the engineering warlocks start their magic, ask them to be specific about their premonitions. Demand they define the problem narrowly – between two elements of the best embodiment; demand they describe the physical mechanisms behind the problem (warlocks are no match for physics); demand they define the problem narrowly in time – when the system spools up, when it slows down, just before it gets hot, right after it cools down. What the warlocks quickly learn is the problem is not the uncertainty around the new idea; the problem is the uncertainty of their knowledge. After several clashes with the talisman of physics, they take off their funny pointy hats, put away their wands, and start contributing in a constructive way. They’re now in the right frame of mind to obsolete their best work

Uncertainty is not bad. Denying it exists is bad, and pretending we can eliminate it is bad. It’s time to demonstrate Potter-like behavior and name what others dare not name.

Uncertainty, Uncertainty, Uncertainty.

 ¹ Remus Lupin

Things aren’t impossible on their own, our thinking makes them so.

Impossible is not about the thing itself, it’s a statement about our state of mind.

When we say impossible, we really say we lack confidence to try.

When we say impossible, we really say we are too afraid to try.

The mission of impossible is to shut down all possibility of possibility.

To soften it, we say almost impossible, but it’s the same thing.

When we say impossible, we make a big judgment – but not about the thing – about ourselves.

Whether it’s a top-down initiative or a bottom-up revolution, your choice will make or break it.

When you have the inspiration for a bottom-up revolution, you must be brave enough to engage your curiosity without self-dismissing. You’ll feel the automatic urge to self-reject – that will never work, too crazy, too silly, too loony – but you must resist. (Automatic self-rejection is the embodiment of your fear of failure.) At all costs you must preserve the possibility you’ll try the loony idea; you must preserve the opportunity to learn from failure; you must suspend judgment.

Now it’s time to tell someone your new thinking. Summon the next level of courage, and choose wisely. Choose someone knowledgeable and who will be comfortable when you slather them with the ambiguity. (No ambiguity, no new thinking.) But most importantly, choose someone who will suspend judgment.

You now have critical mass – you, your partner in crime, and your bias for action. Together you must prevent the new thinking from dying on the vine. Tell no one else, and try it. Try it at a small scale, try it in your garage. Fail-learn-fail until you have something with legs. Don’t ask. Suspend judgment, and do.

And what of top down initiatives? They start with bottom-up new thinking, so the message is the same: suspend judgment, engage your bias for action, and try it. This is the precursor to the thousand independent choices that self-coordinate into a top-down initiative.

New thinking is a choice, and turning it into action is another. But this is your mission, if you choose to accept it.

I will be holding a half-day Workshop on Systematic DFMA Deployment on June 13 in RI. (See bottom of linked page.)  I look forward to meeting you in person.

As an engineering leader you have the biggest profit lever in the company. You lead the engineering teams, and the engineering teams design the products. You can shape their work, you can help them raise their game, and you can help them change their thinking. But if you don’t win their hearts and minds, you have nothing.

Engineers must see your intentions are good, you must say what you do and do what you say, and you must be in it for the long haul. And over time, as they trust, the profit lever grows into effectiveness. But if you don’t earn their trust, you have nothing.

But even with trust, you must be light on the tiller. Engineers don’t like change (we’re risk reducing beings), but change is a must. But go too quickly, and you’ll go too slowly. You must balance praise of success with praise of new thinking and create a standing-on-the-shoulders-of-giants mindset. But this is a challenge because they are the giants – you’re asking them to stand on their own shoulders.

How do you know they’re ready for new thinking? They’re ready when they’re willing to obsolete their best work and to change their work to make it happen. Strangely, they don’t need to believe it’s possible – they only need to believe in you.

Now the tough part: There’s a lot of new thinking out there. Which to choose?

Whatever the new thinking, it must make sense at a visceral level, and it must be simple. (But not simplistic.) Don’t worry if you don’t yet have your new thinking; it will come. As a seed, here are my top three new thinkings:

Define the problem. This one cuts across everything we do, yet most underwhelm it. To get there, ask your engineers to define their problems on one page. (Not five, one.) Ask them to use sketches, cartoons, block diagram, arrows, and simple nouns and verbs.  When they explain the problem on one page, they understand the problem. When they need two, they don’t.

Test to failure. This one’s subtle but powerful. Test to define product limits, and don’t stop until it breaks. No failure, no learning. To get there, resurrect the venerable test-break-fix cycle and do it until you run out of time (product launch.) Break the old product, test-break-fix the new product until it’s better.

Simplify the product. This is where the money is. Product complexity drives organizational complexity – simplify the product and simply everything. To get there, set a goal for 50% part count reduction, train on Design for Assembly (DFA), and ask engineering for part count data at every design review.

I challenge you to challenge yourself: I challenge you to define new thinking; I challenge you to help them with it; I challenge you to win their hearts and minds.

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 for Manufacturing (DFM) is all about reducing the cost of piece-parts. Design for Assembly is all about reducing the cost of putting things together (assembly).  What’s often forgotten is that function comes first.  Change the design to reduce part cost, but make sure the product functions well.  Change the parts (eliminate them) to reduce assembly cost, but make sure the product functions well.

Paradoxically, DFM and DFA are all about function.

Here’s a link to a short video that explains DFM and DFA: link to video. (and embedded below)

Our organizations are set up in silos, and we’re measured that way. (And we wonder why we get local optimization.) At the top of engineering is the VP of the Red Team, who is judged on what it does – product.  At the top of manufacturing is the VP of the Blue Team, who is judged on how to make it – process. Red is optimized within Red and same for Blue, sometimes with competing metrics.  What we need is Purple behavior.

Here’s a link to a short video (1:14): Organizationally Challenged

And embedded below:

Let me know what you think.

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.

I think we underestimate the power of now, and I think we waste too much emotional energy on the past and future.

We use the past to create self-inflicted paralysis, to rationalize inaction. We dissect our failures to avoid future missteps, and push progress into the future. We make no progress in the now. This is wrong on so many levels.

In all written history there has never been a mistake-free endeavor. Never. Failure is part of it. Always. And learning from past failures is limited because the situation is different now: the players are different, the technology is different, the market is different, and the problems are different. We will make new mistakes, unpredictable mistakes. Grounding ourselves in the past can only prepare us for the previous war, not the next one.

Like with the past, we use the future’s uncertainty to rationalize inaction, and push action into the future. The future has not happened yet so by definition it’s uncertain. Get used to it. Embrace it. I’m all for planning, but I’m a bigger fan of doing, even at the expense of being wrong. Our first course heading is wrong, but that doesn’t mean the ship doesn’t sail. The ship sales and we routinely checks the heading, regularly consults the maps, and constantly monitors the weather. Living in the now, it’s always the opportunity for a course change, a decision, or an action.

The past is built on old thinking, and it’s unchangeable – let it go. Spend more emotional energy on the now. The future is unpredictable an uncontrollable, and it’s a result of decisions made in the now – let it go. Spend more energy on the now.

It’s tough to appreciate the power of now, and maybe tougher to describe, but I’ll take a crack at it. When we appreciate the power of now we have a bias for action; we let go of the past; we speculate on the future and make decisions with less than perfect information; and we constantly evaluate our course heading.

Give it a try. Now.