You're optimizing the manufacturing process. How can you ensure design changes have a positive impact?

Before implementing any design changes, it's essential to conduct a thorough analysis of their potential impact. This includes evaluating how the modifications will affect the manufacturing workflow, material requirements, and overall product functionality. Utilize simulation software to predict outcomes and identify any areas that might become bottlenecks. By understanding the ramifications of design alterations, you can make informed decisions that enhance rather than hinder the manufacturing process.

Things to consider. Look at upstream and downstream while you're capturing data. When looking to improve, and balancing forkflow there can be opportunities in both directions, and times that things must happen upstream to make the changes viable long term.

To ensure design changes positively impact the manufacturing process, conduct thorough testing and simulations before implementation. Collaborate with cross-functional teams, including design, engineering, and production, to assess feasibility and potential impacts. Monitor key performance indicators (KPIs) and gather feedback from the production floor to make data-driven adjustments. Pilot changes on a small scale before full rollout to identify and resolve issues early.

Before any analysis or change, you need to know your current process - don't assume you know it! Work wth the process team (subject matter experts) to document or map exactly how the process flows currently - not how it should, but how it does! Including processes down and up stream (no use saving pennies in one process to cost pounds in other). This exercise alone with unearth improvements and give you an insight in to current frustration.

To make sure design changes improve the manufacturing process, test the changes with prototypes, use data to see if things get better, and get feedback from different team members to catch any problems early. Keep checking results and make adjustments as needed.

Conducting thorough root cause analysis to identify areas for improvement. Collaborating with cross-functional teams to develop and review design changes. Using simulation tools and modeling to test and validate design changes before implementation. Implementing a phased rollout to test changes on a small scale before full implementation. Establishing clear performance metrics to measure the impact of design changes. Continuously monitoring and analyzing data to identify areas for further improvement. Soliciting feedback from production staff and incorporating their insights into design decisions. Documenting changes and lessons learned to improve future design iterations.

Firstly you need to understand what your desired outcomes are. What efficency modeling have you undertaken through a gap analysis. What unknowns have you taken into consideration as part of your gap analysis.

Data Collection and Analysis: Gather quantitative and qualitative data before and after design changes to measure performance metrics such as efficiency, cost, and quality. Simulation and Modeling: Use software tools to simulate the impact of design changes on the manufacturing process to predict potential outcomes. Pilot Testing: Implement changes on a small scale first to observe effects and gather data before full-scale implementation. Benchmarking: Compare the new design's performance against industry standards or past performance to evaluate improvements.

Discuss techniques like lean manufacturing, waste reduction, and eco-friendly materials. Analyze how automation is reshaping workforce needs and the importance of reskilling. Encourage manufacturing engineers to take an active role in mentoring and training the next generation of talent. Urge engineers to innovate with sustainability in mind, fostering a culture of environmental responsibility Explore emerging trends in sustainable manufacturing and regulatory pressures.

It's crucial to involve all stakeholders early in the design change process. This includes not only engineers and designers but also production staff, quality control teams, and even end-users if possible. Their insights can reveal practical considerations and potential issues that might not be apparent from a purely technical perspective. Open communication ensures that everyone's expertise contributes to a more effective and cohesive manufacturing strategy.

A company definitely does engage all cross functional teams and vendors to analyze impact. Be sure you had enough communication with customer either through the prototype or pilot testing before finalizing for production and optimizing it.

Involve Cross-Functional Teams: Include input from various departments (engineering, production, quality control, supply chain) to get a comprehensive perspective. Communication Channels: Establish clear communication channels to keep all stakeholders informed about design changes and their expected impacts. Feedback Sessions: Regularly hold meetings and workshops to gather feedback from employees who will be affected by the changes. Stakeholder Buy-In: Ensure that key decision-makers are involved and support the changes to facilitate smoother implementation.

Involve all relevant stakeholders, such as engineers, production staff, and suppliers, in the decision-making process. For instance, if a software company is planning a major update, it should gather feedback from developers, testers, and users to ensure the changes meet their needs.

For the stakeholder's engagement to be truthfully and to be consistent, we need to create a value chain that is interconnected. Main issue these days is the continuous search for pricing and for better margins in our bucket, and then not understanding that if the other stakeholders do not create value as well, we will never have a good service or product as we should.

Iterative Prototyping: Develop and test prototypes iteratively to identify and resolve issues early. Automated Testing: Implement automated testing systems to continuously monitor the impact of changes and identify any deviations from expected results. Performance Metrics: Regularly track and analyze performance metrics to assess the effectiveness of design changes. Adaptability: Be prepared to make further adjustments based on test results to optimize the design continuously.

Following 3 Things are pretty important 1.Simulation at design level - can build a user community and engage them for feedbacks too. 2.Functionality testing in the team level 3.functional and User experience testing at the customer level

Implement a robust testing protocol to evaluate the effectiveness of design changes in real-world conditions. A medical device company, for example, might conduct clinical trials to assess the performance of a new implant design before full-scale production.

I think this is the most avoided part of manufacturing. Most manufacturers do not understand the value of testing because they think it as a waste of time. Testing departments are really a must.

I get the feeling I'm reading a column written with AI and then commented on by folks also using AI. Am I wrong on this? It's like the TV is talking to the toaster (digital of course).

Value Stream Mapping: Identify and eliminate non-value-adding activities to streamline the manufacturing process. Just-In-Time Production: Ensure that design changes support just-in-time production to reduce waste and improve efficiency. Continuous Improvement (Kaizen): Foster a culture of continuous improvement where small, incremental changes are regularly implemented and assessed. Standardization: Standardize processes and components to reduce variability and improve consistency in manufacturing.

Engaging with user is the key factor at all stages right from PoC, MVP to end product to make conscious decisions on reducing unnecessary features, which in turn helps in reducing assembly time, waste and time to market.

Adopt lean manufacturing principles to minimize waste and maximize efficiency. A furniture manufacturer, for example, could use just-in-time inventory management to reduce storage costs and improve production flow.

If the manufacturers do not use lean, they are simply losing money. Like a good friend uses to say, better to go home and sleep, then to lose money. Lean is not even optional, is mandatory, and so many factories are not using it.

Ensuring egos are kept in check is crucial to the success of the feedback loop. If employees are not willing to give feedback, you will fail. Anonymous feedback loops also fail here, it only prevents direct rebuttal and doesn't go to work on the mindset necessary for being successful in a continuous improvement culture.

Establish a feedback loop to gather data on the performance of design changes and identify areas for further improvement. A smartphone manufacturer, for instance, might analyze user reviews and technical support data to pinpoint issues with a new model and make necessary adjustments.

Regular Reviews: Schedule regular review meetings to discuss the progress and impact of design changes. Employee Input: Encourage employees to provide ongoing feedback on the changes and suggest further improvements. Customer Feedback: Collect and analyze feedback from customers to understand the impact of design changes on product satisfaction and quality. Data-Driven Decisions: Use feedback data to make informed decisions about future design changes and process improvements.

Another thing the manufacturing is not using properly. Mistakes happen in processes, things vary at times, and if we do not have good feedback loop, we will keep doing the same mistakes and having the same variability all the time.

I would conduct Failure Mode Effects Analysis(FMEA)on the process. This is a great Lean tool that helps identify risk and opportunity. From there you can rank the highest risk items and develop a solution plan and control plan to mitigate them. I would also consider if there is a chance to conduct a couple of rapid experiments with the solution where applicable to ensure smoother implementation of solutions.

By understanding the lowest risk route, you'll have a better insight into the consequences of not following it. This allows your process to have flexibility when required, but you'll also have the power of knowledge to help mitigate the negative impacts. COVID was a great example, that processes need to be flexible!

Risk Assessment: Conduct a thorough risk assessment before implementing design changes to identify potential issues and their impact. Mitigation Strategies: Develop and implement strategies to mitigate identified risks, such as contingency plans and backup processes. Monitoring and Control: Continuously monitor for potential risks and deviations from expected outcomes, and take corrective action as needed. Documentation: Maintain comprehensive documentation of risks, mitigation strategies, and lessons learned to inform future design changes.

risks can be related to following aspects of the product functional / Quality - Either due to Mfg. Technology, vendor or design. Material Cost/Unavailability - Geography of the vendor, lack of support from vendor, policies made by the country we reside in with respect to imports. Manufacturing time - complexity in the design/assembly, Material quality/grade, vendor inefficiency/miscommunication Logistics - Mfg. and assembly locations, number of places product goes for mfg., assembly and testing before it reaches consumer.

Impact Assessment: Consider All Facets: Evaluate the design changes not just in isolation, but how they will affect the entire manufacturing process. Analyze potential upstream and downstream impacts on materials, equipment, and other processes. Cost-Benefit Analysis: Carefully consider the costs associated with implementing the design changes (materials, equipment modifications, training) and weigh them against the anticipated benefits (increased efficiency, reduced waste, etc.).