Shipulski On Design

Archive for the ‘How To’ Category

People try to diminish when they’re threatened.

People are threatened when they think you’re more capable than they are.

When they think less of themselves, they see you as more capable.

There you have it.

When someone doesn’t do what they say and you bring it up to them, there are two general responses. If they forget, they tell you and apologize.  If they don’t have a good reason, they respond defensively.

When someone responds defensively, it means they know what they did.

They respond defensively when they know what they did and don’t like what it says about them.

Defensiveness is an admission of guilt.

Defensiveness is an acknowledgment that the ego was bruised.

Defensiveness is a declaration self-worth is insufficient.

People can either stand down or turn it up when defensiveness is called by name.

When people stand down, they demonstrate they have what it takes to own their behavior.

When they turn it up, they don’t.

When people turn their defensiveness into aggressiveness, they’re unwilling to own their behavior because doing so violates their self-image. And that’s why they’re willing to blame you for their behavior.

When you tell someone they didn’t do what they said and they acknowledge their behavior, praise them.  Tell them they displayed courage. Thank them.

When you call someone on their defensiveness and they own their behavior, compliment them for their truthfulness.  Tell them their truthfulness is a compliment to you. Tell them their truthfulness means you are important to them.

When you call someone on their defensiveness and they respond aggressively, stand tall. Recognize they are threatened and stand tall.  Recognize they don’t like what they did and they don’t have what it takes (in the moment) to own their behavior. And stand tall.  When they try to blame you, tell them you did nothing wrong. Tell them it’s not okay to try to blame you for their behavior. And stand tall.

It’s not your responsibility to teach them or help them change their behavior.  But it is your responsibility to stay in control, to be professional, and to protect yourself.

When you stand tall, it means you know what they’re doing.  When you stand tall, it means it’s not okay to behave that way.  When you stand tall, it means you are comfortable describing their behavior to those who can do something about it.  When you continue to stand tall, you make it clear there is nothing they can do to prevent you from standing tall.

In the future, they may behave defensively and aggressively with others, but they won’t behave that way with you.  And maybe that will help others stand tall.

Image credit — Johan Wieland

If you got what you wanted, what would you do?

Would you be happy or would you want something else?

Wanting doesn’t have a half-life.  Regardless of how much we have, wanting is always right there with us lurking in the background.

Getting what you want has a half-life. After you get what you want, your happiness decays until what you just got becomes what you always had.  I think they call that hedonistic adaptation.

When you have what you always had, you have two options.  You can want more or you can want what you have.  Which will you choose?

When you get what you want, you become afraid to lose what you got.  There’s no free lunch with getting what you want.

When you want more, I can manipulate you. I wouldn’t do that, but I could.

When you want more your mind lives in the future where it tries to get what you want.  And lives in the past where it mourns what you did not get or lost.

It’s easier to live in the present moment when you want what you have. There’s no need to craft a plan to get more and no need to lament what you didn’t have.

You can tell when a person wants what they have.  They are kind because there’s no need to be otherwise.  They are calm because things are good.  And they are themselves because they don’t need anything from anyone.

Wanting what you have is straightforward.  Whatever you have, you decide that’s what you want. It’s much different than having what you want.  Once you have what you want hedonistic adaptation makes you want more, and then it’s time to jump back on the hamster wheel.

Wanting what you have is freeing.  Why not choose to be free and choose to want what you have?

Image credit — Steven Guzzardi

You know the space is new when you don’t have the right words to describe the phenomenon.

When there are two opposite sequences of events and you think both are right, you know the space is new.

You know you’re thinking about new things when the harder you try to figure it out the less you know.

You know the space is outside your experience but within your knowledge when you know what to do but you don’t know why.

When you can see the concept in your head but can’t drag it to the whiteboard, you’re swimming in new soup.

When you come back from a walk with a solution to a problem you haven’t yet met, you’re circling new space.

And it’s the same when know what should be but it isn’t – circling new space.

When your old tricks are irrelevant, you’re digging in a new sandbox.

When you come up with a new trick but the audience doesn’t care – new space.

When you know how an experiment will turn out and it turns out you ran an irrational experiment – new space.

When everyone disagrees, the disagreement is a surrogate for the new space.

It’s vital to recognize when you’re swimming in a new space.  There is design freedom, new solutions to new problems, growth potential, learning, and excitement.  There’s acknowledgment that the old ways won’t cut it.  There’s permission to try.

And it’s vital to recognize when you’re squatting in an old space because there’s an acknowledgment that the old ways haven’t cut it.  And there’s permission to wander toward a new space.

Image credit — Tambaco The Jaguar

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

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

Put it out there.  You don’t have time to do otherwise.

Be true to yourself.  No one deserves that more than you do.

Tell the truth, even when it’s difficult for people to hear.  They’ll appreciate your honesty.

Believe the actions and not the words.  Enough said.

Learn to listen to what is not said.  That’s usually the juicy part.

Say no to good projects so you can say yes to great ones.

Say what you will do and do it.  That’s where trust comes from.

Deliver praise in public.  Better yet, deliver praise in front of their spouse.

Develop informal networks.  They are more powerful than the formal org chart.

Learn to see what’s not happening.  You’ll understand what’s truly going on.

Help people.  It’s like helping yourself twice.

Don’t start a project you’re not committed to finishing. There’s no partial credit with projects.

Do the right thing, even if it comes at your expense.

And be your best self.  Isn’t that what you do best?

Image credit — Tambako The Jaguar

Tell me what you want done, but don’t tell me how. You’ve got to leave something for me.

Better yet, ask me to help you with a problem and let me solve it.  I prefer asking over telling.

Better still, explain the situation and ask me what I think.  We can then discuss why I see it the way I do and we can create an approach.

Even better, ask me to assess the situation and create a proposal.

Better still, ask me to assess the situation, create a project plan, and run the project.

If you come up with a solution but no definition of the problem, I will ask you to define the problem.

If you come up with a solution and a definition of the problem, I will ask you to explain why it’s the right solution.

If you come up with a problem, a solution, and an analysis that justifies the solution, I will ask why you need me.

If you know what you want to do, don’t withhold information and make me guess.

If you know what you want to do, ask me to help and I will help you with your plan.

If you know what you want to do and want to improve your plan, ask me how to make your plan better.

If you want your plan to become our plan, bring me in from the start and ask me what I think we should do.

Image credit — x1klima

Software may be eating the world, but the hardware elements of a startup’s work define when lunch is served.

Hardware takes longer than software.  With hardware, after the product and its parts are designed, companies are vetted/selected to make the parts; contracts are signed to make the parts; the parts are made; the parts are shipped; the parts are received; the parts are inspected; and the parts are put in their locators.  Then, the manufacturing process is defined, the manufacturing tooling is designed and purchased; the manufacturing documentation is created; the final test system is designed and built; and the parts are assembled into the product. Then, the product is run through final test and tested for robustness.  After it’s learned the manufacturing process created too much variation and the insufficient robustness manifests, the manufacturing process and its documentation are changed to reduce variation; the parts that failed are redesigned, purchased, made, shipped, and received; and the next iteration of the product is built and tested.  This process is repeated until the product is robust and the manufacturing process is repeatable.  This is why hardware takes longer than software.

If the software is done but the hardware isn’t, the software must wait for the hardware and the customer must wait for the finished product. To get the hardware done faster, recognize that redesign loops are part of the game and invest in the capability to iterate quickly.  Line up the suppliers to make parts quickly; keep utilization low on the support resources so they can jump on the work when it arises (think fire stations who can respond quickly when there’s a fire); and avoid part-time resources on the critical path.  There may be other things to focus on, but only after taking care of these three.

Software may be eating the world, but the hardware elements of a startup’s work govern the cost of getting to the dinner table.

Hardware costs more to make than software.  Hardware is made of steel, aluminum, injection molded plastics, and rare earth elements, all of which cost money.  And because startups do things that have not been done before, the materials can be special (costly).  And unlike software, the marginal cost of an incremental unit is non-zero.  With hardware, if you want to make another one you’ve got to buy more of the materials; you have to pay people to make it; you have to buy/build the manufacturing system; you have to buy the measurement systems and engineering infrastructure; and you have to pay people to break-test-fix the product until it’s ready.

What’s a startup to do?

To do hardware faster, focus on learning.  And to do hardware more cost-effectively, focus on learning.

For both time and money, learning efficiency is a good starting point.  The most efficient learning is the learning you don’t have to do, so be ruthless in how you decide what you DON’T learn. Where possible, declare all but the most vital problems as annoyances and save them for later. (Annoyances don’t require learning.)  This will concentrate your precious resources on fewer problems, improve your learning rate, and keep costs to a minimum.

Here’s a good test to decide if the learning is worth learning.  Ask yourself “If we accomplish this learning objective, how will the customer benefit?”  If there is low or no customer benefit, say no to the learning objective.  If there is medium customer benefit, say no to the learning objective.  If there is significant customer benefit, do the learning.

For those learning objectives that make it through the gauntlet, learn what you need to learn, but no more.  To do this, create a formal learning objective: “We want to learn [enter learning objective here].”  With learning objectives, the tighter the better. And define the criteria for decision making: “If the result of the test is [define objective measurement here], we will decide [enter decision here].” With decision criteria, the clearer the better.

Learn effectively, not elegantly.  Be bold, rough, and crude with how you learn.  Design tests that take advantage of the resources you have on hand so you can learn quickly.  If you can run a crude test in one hour and the perfect test will take a week, run three crude tests and be done by the end of the day.

Learn with less confidence and more judgment.  If a wrong decision can be overcome quickly and with low cost, be less confident and use more judgment.

Whether driven by hardware, software, or the integration of both, project completion is governed by the critical path.  And with longer time constants, it’s more likely that the hardware defines the critical path.  The total cost of the project is the sum of the three costs: software, hardware, and integration.  And because hardware requires expensive materials, factories, engineering labs, people to run the tests, and people to make the products, hardware is likely a large percentage of the project costs.

Image credit — Günter Hentschel