Shipulski On Design

Archive for October, 2017

Creativity and innovation are dominated by uncertainty. And in the domain of uncertainty, not only are the solutions unknown, the problems are unknown. And yet, we still try to use the tried-and-true toolbox of certainty even after it’s abundantly clear those wrenches don’t fit.

When wallowing in the mud of uncertainty and company leaders ask, “When will you be done?”, the only real answer is a description of the next thing you’ll try to learn. “We will learn if Step 1 is possible.” And then the predicted response, “Well, when will you be done with that?”  The only valid response is, “It depends.”  Though truthful, this goes over like a lead balloon.  And the dialog continues – “Okay, then, what is Step 2?”  The unpalatable answer, “It depends. If Step 1 is successful, we’ll move onto Step 2, but if Step 1 is unsuccessful, we’ll step back and regroup.” This, too, though truthful, is unsatisfactory.

When doing creative work, there’s immense pressure to be done on time. But, that pressure is inappropriate. Yes, there can be pressure to learn quickly and effectively, but the expectation to be done within an arbitrary timeline is ludicrous.  Managers don’t know this, but when they demand a completion date for a task that has never been done before, the people doing the creative work know the manager doesn’t know what they’re doing.  They won’t tell the manager what they think, but they definitely think it. And when pushed to give a completion date, they’ll give one, knowing full well the predicted date is just as arbitrary as the manager’s desired timeline.

But learning objectives can create common ground. Starting with “We want to learn if…”, learning objectives define what the project team must learn. Though there’s no agreement on when things will be completed, everyone can agree on the learning objectives. And with clearly defined learning objectives and measurable definitions of success, the project can move forward with consensus. There is still consternation over the lack of hard deadlines for the learning objectives, but there is agreement on the sequence of events, tests protocols or analyses that will be carried out to learn what must be learned.

Two rules to live by: If you know when you’ll be done, you’re not doing innovation. And if no one is surprised by the solution, you’re not doing creative work.

Image credit – Michael Carian

The race for productivity is on. And to take productivity to the next level, set limits.

To reduce the time wasted by email, limit the number of emails a person can send to ten emails per day. Also, eliminate the cc function. If you send a single email to ten people, you’re done for the day.  This will radically reduce the time spent writing emails and reduce distraction as fewer emails will arrive. But most importantly, it will help people figure out which information is most important to communicate and create a natural distillation of information. Lastly, limit the number of word in an email to 100. This will shorten the amount of time to read emails and further increase the density of communications.

If that doesn’t eliminate enough waste, limit the number of emails a person can read to ten emails per day.  Provide the subject of the email and the sender, but no preview.  Use the subject and sender to decide which emails to read.  And, yes, responding to an email counts against your daily sending quota of ten.  The result is further distillation of communication. People will take more time to decide which emails to read, but they’ll become more productive through use of their good judgement.

Limit the number of meetings people can attend to two per day and cap the maximum meeting length to 30 minutes. The attendees can use the meeting agenda, meeting deliverables and decisions made at the meeting to decide which meetings to attend. This will cause the meeting organizers to write tight, compelling agendas and make decisions at meetings. Wasteful meetings will go away and productivity will increase.

To reduce waiting, limit the number of projects a person can work on to a single project.  Set the limit to one. That will force people to chase the information they need instead of waiting. And if they can’t get what they need, they must wait. But they must wait conspicuously so it’s clear to leaders that their people don’t have what they need to get the project done. The conspicuous waiting will help the leaders recognize the problem and take action.  There’s a huge productivity gain by preventing people from working on things just to look busy.

Though harsh, these limits won’t break the system. But they will have a magical influence on productivity. I’m not sure ten is the right number of emails or two is the right number of meetings, but you get the idea – set limits.  And it’s certainly possible to code these limits into your email system and meeting planning system.

Not only will productivity improve, happiness will improve because people will waste less time and get to use their judgement.

Everyone knows the systems are broken. Why not give people the limits they need and make the productivity improvements they crave?

Image credit –  XoMEoX

With innovation, novel solutions pay the bills – a new solution provides new value for the customer and the customer buys it from you.  The trick, however, is to come up with novel solutions.  To improve the rate and quality of novel solutions, there’s usually a focus on new tools, new problem-solving methods and training on both. The idea is get better at moving from problem to solution.  There’s certainly room for improvement in our problem-solving skills, but I think the pot of gold is hidden elsewhere.

Because novel solutions reside in uncharted design space, it follows that novel solutions will occur more frequently if the problem-solvers are pointed toward new design space.  And to make sure they don’t solve in the tired, old design space of success, constraints are used to wall it off.  Rule 1 – point the solvers toward new design space. Rule 2 – wall off the over-planted soil of success.

The best way to guide the problems solvers toward fertile design space is to create different problems for them to solve. And this guide-the-solvers thinking is a key to the success of the IBE (Innovation Burst Event), where Design Challenges are created in a way that forces the solvers from the familiar. And it’s these Design Challenges that ARE the new problems that bring the new solutions.  And to wall off old design space, the Design Challenges use creatively curated constraints to make it abundantly clear that old solutions won’t cut it.

Before improving the back-end problem solving process, why not change the front- end problem selecting process?

Chose to solve different problems, then learn to solve them differently.

Image credit – Rajarshi MITRA

Additive Manufacturing (AM) is technology/product space with ever-increasing performance and an ever-increasing collection of products. There are many different physical principles used to add material and there are a range of part sizes that can be made ranging from micrometers to tens of meters.  And there is an ever-increasing collection of materials that can be deposited from water soluble plastics to exotic metals to specialty ceramics.

But AM tools and technologies don’t deliver value on their own.  In order to deliver value, companies must deploy AM to solve problems and implement solutions.  But where to start? What to do next? And how do you know when you’ve arrived?

To help with your AM journey, below a maturity model for AM.  There are eight categories, each with descriptions of increasing levels of maturity.  To start, baseline your company in the eight categories and then, once positioned, look to the higher levels of maturity for suggestions on how to move forward.

For a more refined calibration, a formal on-site assessment is available as well as a facilitated process to create and deploy an AM build-out plan.  For information on on-site assessment and AM deployment, send me a note at mike@shipulski.com.

Execution

1. Specify AM machine – There a many types of AM machines. Learn to choose the right machine.
2. Justify AM machine – Define the problem to be solved and the benefit of solving it.
3. Budget for AM machine – Find a budget and create a line item.
4. Pay for machine –  Choose the supplier and payment method – buy it, rent to own, credit card.
5. Install machine – Choose location, provide necessary inputs and connectivity
6. Create shapes/add material – Choose the right CAD system for the job, make the parts.
7. Create support/service systems – Administer the job queue, change the consumables, maintenance.
8. Security – Create a system for CAD files and part files to move securely throughout the organization.
9. Standardize – Once the first machines are installed, converge on a small set of standard machines.
10. Teach/Train – Create training material for running AM machine and creating shapes.

Solution

1. Copy/Replace – Download a shape from the web and make a copy or replace a broken part.
2. Adapt/Improve – Add a new feature or function, change color, improve performance.
3. Create/Learn – Create something new, show your team, show your customers.
4. Sell Products/Services – Sell high volume AM-produced products for a profit. (Stretch goal.)

Volume

1. Make one part – Make one part and be done with it.
2. Make five parts – Make a small number of parts and learn support material is a challenge.
3. Make fifty parts – Make more than a handful of parts. Filament runs out, machines clog and jam.
4. Make parts with a complete manufacturing system – This topic deserves a post all its own.

Complexity

1. Make a single piece – Make one part.
2. Make a multi-part assembly – Make multiple parts and fasten them together.
3. Make a building block assembly – Make blocks that join to form an assembly larger than the build area.
4. Consolidate – Redesign an assembly to consolidate multiple parts into fewer.
5. Simplify – Redesign the consolidated assembly to eliminate features and simplify it.

Material

1. Plastic – Low temperature plastic, multicolor plastics, high performance plastics.
2. Metal – Low melting temperature with low conductivity, higher melting temps, higher conductivity
3. Ceramics – common materials with standard binders, crazy materials with crazy binders.
4. Hybrid – multiple types of plastics in a single part, multiple metals in one part, custom metal alloy.
5. Incompatible materials – Think oil and water.

Scale

1. 50 mm – Not too large and not too small. Fits the build area of medium-sized machine.
2. 500 mm – Larger than the build area of medium-sized machine.
3. 5 m – Requires a large machine or joining multiple parts in a building block way.
4. 0.5 mm – Tiny parts, tiny machines, superior motion control and material control.

Organizational Breadth

1. Individuals – Early adopters operate in isolation.
2. Teams – Teams of early adopters gang together and spread the word.
3. Functions – Functional groups band together to advance their trade.
4. Supply Chain – Suppliers and customers work together to solve joint problems.
5. Business Units – Whole business units spread AM throughout the body of their work.
6. Company – Whole company adopts AM and deploys it broadly.

Strategic Importance

1. Novelty – Early adopters think it’s cool and learn what AM can do.
2. Point Solution – AM solves an important problem.
3. Speed – AM speeds up the work.
4. Profitability – AM improves profitability.
5. Initiative – AM becomes an initiative and benefits are broadly multiplied.
6. Competitive Advantage – AM generates growth and delivers on Vital Business Objectives (VBOs).

Image credit – Cheryl