Shipulski On Design

Archive for the ‘Level 5 Courage’ Category

When asked how to improve manufacturing, the recipe is clear: lean.  When asked how to improve engineering, the recipe: there isn’t one.  Each engineering improvement effort is unique; though there are common themes and building blocks, each has its own fingerprint.

Each company has its own strengths, weaknesses, opportunities and threats; each company has unique products and markets; each its own goals; each its own culture; each its own future state. Informed by uniqueness, the recipe is unique. To create your unique improvement recipe, I suggest WHY, WHAT, HOW.

WHY
Before your engineering improvement recipe can be formed, the fundamental shaping question must be answered.  Take a breath, fire up your laptop, put on your headphones, and queue up your best music. Type this question:

WHY does our business demand we improve engineering?

Now, type the answer. (Literally.) Use nouns and verbs to explain why engineering must improve. If you can’t, stop. Without a clear, concise, jargon-free answer nothing can be done to advance the cause.  (Though there can be plenty of activity, there can be no progress.) Without the WHY, you cannot pass GO.  You must create a clear, concise WHY.

Seek out help from trustworthy people to create the WHY. Don’t move forward until you understand it well enough to explain it to the engineering organization.  Now, with WHY in place, it’s time for WHAT.

WHAT
Informed by WHY, it’s time for WHAT. Secure a quiet spot, scare up a big piece of paper, and grab your favorite pen. On the top of the page, write this question:

WHAT does engineering improvement look like?

Now, draw the picture. (Literally.) Use sketches, scribbles, arrows, blocks, and people’s names to describe what improved engineering looks like.  Sit in the future and describe it in present tense.  Once drawn, review it with folks you trust, revise it, and repeat.  If you cannot draw the future, keep trying.  Once you have something, review it with folks you trust, revise it, and repeat. Don’t move forward until you draw it clearly enough to explain it to the engineering organization. And with WHAT in place, it’s time for HOW.

HOW
The first step of HOW is similar to WHAT. Pick up your favorite pen, come back to the now, and draw a picture of today’s engineering capabilities, engineering’s current state.  Again, use scribbles, blocks, arrows, and names.

The second step is to define the difference between future and current states.  With future and current state pictures side-by-side, perform a mathematical subtraction: future state – current state.  The difference is HOW. A block in future state that’s not part of the current state is a new thing that must be created; a new arrow in the future state is an activity, interaction, or relationship that must be created; a new person, named or unnamed, represents new thinking. Things that appear in both states are strengths to build on.

The third step, prioritization.  Start here:

What engineering strengths will we build on?

It’s important start with strengths. It sends the right message to the engineering organization: we must build on build on what works, build on what got us here. Engineers need to know that, fundamentally, their work is good, and major building blocks are in place, the foundation is solid.

What development areas will we improve?

Take care with this one.  To avoid a demoralized engineering team, there should be fewer development areas than strengths.  Though there may be many development areas, call out only the most important.

What’s the right first bite?

The most important improvements are those that strongly support the WHY; there’s a natural sequence of things (socks before shoes) that must be respected;  and there’s a finite amount of work that can be done.  Use these three lenses as the start of a prioritization framework.

Building blocks for engineering improvement are the same for all companies: people, tools, and processes, but there are many types of people, countless engineering tools, and all processes can be improved. WHY, WHAT, HOW can help define your unique improvement fingerprint: the right people, the right tools, the right processes, shaped by your unique company goals, and improved in right sequence.

We are responsible for our actions, for what we do, for our work, and others are responsible for their response to it. (That’s why they call it responsibility.) Though we know we can’t control others, we still snare ourselves in worry trap: What will they think? Will they like it? What will they say?

Worse than the worry trap, however, is when we actually change our work based on what others will think. A big no-no. We’re asked to do the work because we’re talented, we’re uniquely qualified, we’re the experts. Why do we let opinions of others wield so much power? Who cares what they say. We will let our work speak for itself.

There’s not much in life we have control over, but work is one of them. We control most everything about it: the what and how, the caliber, the tenor. We choose to do marginal work, average work, great work, or magical work.  It’s our choice.  We choose. When we chose to do magical work, its voice powerful enough to drown out the less capable, the politically motivated, and the CEO.

So go do magical work. Do work so good you don’t remember how you did it, so good you don’t think you could do it again, so good it scares you. But be ready – magical work, by definition, is misunderstood.

What will they say about your magic?  It doesn’t matter, magic’s voice will drown them out.

What’s the risk?

What’s to lose?

What’s in the way?

What are you afraid of?

a

Try it.

I think we can turn around the US economy, one company at a time.  Here’s how:

To start, we must make a couple commitments to ourselves.  1. We will do what it takes to manufacture products in the US because it’s right for the country. 2. We will be more profitable because of it.

Next, we will set up a meeting with our engineering community, and we will tell them about the two commitments. (We will wear earplugs because the cheering will be overwhelming.) Then, we will throw down the gauntlet; we will tell them that, going forward, it’s no longer acceptable to design products as before, that going forward the mantra is: half the cost, half the parts, half the time. Then we will describe the plan.

On the next new product we will define cost, part count, and assembly time goals 50% less that the existing product; we will train the team on DFMA; we will tear apart the existing product and use the toolset; we will learn where the cost is (so we can design it out); we will learn where the parts are (so we can design them out); we will learn where the assembly time is (so we can design it out).

On the next new product we will front load the engineering work; we will spend the needed time to do the up-front thinking; we will analyze; we will examine; we will weigh options; we will understand our designs. This time we will not just talk about the right work, this time we will do it.

On the next new product we will use our design reviews to hold ourselves accountable to the 50% reductions, to the investment in DFMA tools, to the training plan, to the front-loaded engineering work, to our commitment to our profitability and our country.

On the next new product we will celebrate the success of improved product functionality, improved product robustness, a tighter, more predictable supply chain, increased sales, increased profits, and increased US manufacturing jobs.

On the next new product we will do what it takes to manufacture products in the US because it’s the right thing for the country, and we will be more profitable because of it.

If you’d like some help improving the US economy one company at a time, send me an email (mike@shipulski.com), and I’ll help you put a plan together.

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p.s. I’m holding a half-day workshop on how to implement systematic cost savings through product design on June 13 in Providence RI as part of the International Forum on DFMA — here’s the link. I hope to see you there.

You solved a big problem in a meaningful way; you made a big improvement in something important; you brought new thinking to an old paradigm; you created something from nothing. Unfortunately, the easy part is over. Your work created the new baseline, the new starting point, the new thing that must be made obsolete.  So now on to the hard part:  to obsolete your best work

You know best how to improve your work, but you must have the right mindset to obsolete it.  Sure, take time to celebrate your success (Remember, you created something from nothing.), but as soon as you can, grow your celebration into confidence, confidence to dismantle the thing you created. From there, elevate your confidence into optimism, optimism for future success. (You earned the right to feel optimistic; your company knows your next adventure may not work, but, hey, no one else will even try some of the things you’ve already pulled off.)  For you, consequences of failure are negligible; for you, optimism is right.

Now, go obsolete your best work, and feel good about it.

Mental walls are more powerful than physical ones.

With physical walls you know where they start and end and know if you can bust them down. With mental walls, you’re not sure.

With physical walls you know they exist – that they’re real. With mental walls, you’re not sure.

With physical walls you can blame someone for bad workmanship. With mental walls, you’re the workman.

The only way to tell a real wall from a mental one is to to take a run at it, but even then, you’re never really sure.

Your product costs are twice what they should be. That’s right. Twice.

You don’t believe me. But why? Here’s why:

If 50% cost reduction is possible, that would mean you’ve left a whole shitpot of money on the table year-on-year and that would be embarrassing. But for that kind of money don’t you think you could work through it?

If 50% cost reduction is possible, a successful company like yours would have already done it. No. In fact, it’s your success that’s in the way. It’s your success that’s kept you from looking critically at your product costs. It’s your success that’s allowed you to avoid the hard work of helping the design engineering community change its thinking. But for that kind of money don’t you think you could work through it?

Even if you don’t believe 50% cost reduction is possible, for that kind of money don’t you think it’s worth a try?

Seeing things as they are takes skill, but doing something about it takes courage. Want an example? Check out movie The Sixth Sense directed by M. Night Shyamalan.

At the start of the film Dr. Malcolm Crowe, esteemed child psychologist, returns home with his wife to find his former patient, Vincent Grey, waiting for him. Grey accuses Crowe of failing him and shoots Crowe in the lower abdomen, then shoots himself.

Cut to a scene three months later where Crowe councils Cole Sear, a troubled, isolated nine year old. Over time, Crowe gains the boy’s trust. The boy ultimately confides in Crow telling him he “Sees dead people that walk around like regular people.” (Talk about seeing things as they are.) Later in the film the boy confides in his mother telling her what he sees. Understandably, his mother does not believe him. But imagine his pain when, after sharing his disturbing reality, his only parent does not support him. (And we get upset when co-workers don’t support our somewhat off-axis realities.) And imagine his courage to move forward.

It takes level 5 courage for him to talk about such a disturbing reality, but Cole Sear is up to the challenge. He so badly wants to change his situation, to shape his future, he does what it takes. Not just talk, but actions. He defines his new future and defines the path to get there. He defines his fears and decides to work through them to create his new future where he is no longer afraid of the dead who seek him out. He changes his go-forward behavior. Instead of hiding, he talks with the dead, understands what they want from him, and helps them. He walks the path.

Ultimately he creates a future that works for him. He convinces his mom that his reality is real; she believes him and supports him and his reality. (That’s what we all want, isn’t it?) His relationships with the dead are non-confrontational and grounded in mutual respect. His stress level is back to mortal levels. His reality is real to people he cares about. But Cole Sear is not done yet.

***** SPOILER ALERT – IF YOU HAVE NOT SEEN THE SIXTH SENSE, READ NO FURTHER ****

In Shyamalan’s classic finish-with-a-twist style, Cole Sear, the scared nine year old boy with his bizarre reality, masterfully convinces his psychologist that his I see dead people reality is real and convinces the psychologist that he’s dead. All along, when the psychologist thought he was helping the boy see things as they are, the boy was helping the psychologist. The little boy who saw dead people convinced the dead psychologist that his seemingly bizarre reality was real.

As Cole demonstrated, seeing things for what they are and doing something about can make a difference in someone’s life.

The DoD wants to save money, but they can’t do it alone. But can they possibly succeed? Do they have fighting a chance? Can they get it done? Wrong pronouns.

Can we possibly succeed?

Do we have a fighting chance?

Can we get it done?

In difficult times it’s easy to be critical of  others, to make excuses, to look outside. (They, they, they.) In difficult times it’s hard find the level 5 courage to be critical ourselves, to take responsibility, to look inside. (We, we, we.) But we must look inside because that’s where the answer is. We know our work best; we’re the only ones who can reinvent our work; we’re the ones who can save money; we’re responsible.

Changing our actions, our work, is scary, but that’s what the DoD is asking for; we must overcome our fear. But to overcome it we must acknowledge it, see it as it is, and work through it.

Here’s the DoD’s challenge: “Contractors – provide us more affordable systems.” There are two ways we can respond.

The fear-based response (the they response): The DoD won’t accept the changes. In fact, they’ve never liked change. They’ll say no to any changes. They always have.

The seeing things as they are response (the we response): We must try, since not trying is the only way to guarantee failure. Things are different now. Change is acceptable. However, the facts are we don’t know what changes to propose, we don’t know what creates cost, and we don’t know how to design low cost, low complexity systems. We were never taught. We need to develop our capability if we’re to be successful.

The they response: Their MIL specs dictate the design and they won’t budge on them. They’ll say no to any changes.  They always have.

The we response: We must try, since not trying is the only way to guarantee failure. Things are different now. Change is acceptable. However, the facts are we don’t know why we designed it that way, we don’t know all that much about the design, we don’t know what creates cost, and we don’t know how to design low cost, low complexity systems. We were never taught. We need to develop our capability if we’re to be successful.

The they response: All they care about is performance. They are driving the complexity. And when push comes to shove, they don’t care about cost. They’ll say no to any changes. They always have.

The we response: We must try, since not trying is the only way to guarantee failure. Things are different now. Change is acceptable. However, the facts are we don’t know what truly controls performance, we don’t know what we can change, we don’t know the sensitivities, we don’t know what creates cost, and we don’t know how to design low cost, low complexity systems. We were never taught. We need to develop our capability if we’re to be successful.

The DoD has courageously told us they want to overcome their fear. Let’s follow their lead and overcome ours.  It will be good for everyone.

We all have computer models – economic models, buying models, voting models, thermal, stress, and vibration. A strange thing happens when our models reside in the computer: their output becomes gospel, unchallengeable. And to set the hook, computerized output is bolstered by slick graphics, auto-generated graphs, and pretty colors.

Model fundamentals are usually well defined, proven, and grounded – not the problem. The problem is applicability. Do the fundamentals apply? Do they apply in the same way? Do different fundamentals apply? We never ask those questions. That’s the problem.

New folks don’t have the context to courageously challenge fundamentals and more experienced folks have had the imagination flogged out of them. So who’s left to challenge applicability of fundamentals? You know who’s left.

It’s smart folks with courage that challenge fundamentals; it’s people willing to contradict previous success (even theirs) that challenge fundamentals; it’s people willing to extend beyond that challenge fundamentals; it’s people willing to risk their career that challenge fundamentals.

Want to challenge fundamentals? Hire, engage, and support smart folks with courage.

Doing new is hard and starting new is particularly hard. Once fear is overcome and new is started, doing new becomes a battle with discouragement. Not managed, discouragement can stop new.

Slumped shoulders and a head hung low are the signs and a mismatch with expectations is the source. Expectations are defined in the form of a project plan, but, since the work is new, expectations are not grounded, not calibrated. How long will it take to do something we’ve never dreamed of doing? Yet when disguised as a project plan, uncalibrated expectations become a hard deadline.

When you want to do new, you give the project to your best. When they use the right tools, the latest data, and the best processes, yet new does not come per the plan, your best can become discouraged. But this discouragement is misplaced. Sure, the outcome is different from the plan, but reality isn’t the problem, it’s the plan, the expectations. They did everything right, so tell them. Tell them the expectations are out of line. Tell them you think their doing a good job. Tell them if it was easy, you’d have given the project to someone else. Tell them they can feel discouraged for five more minutes, but then they’ve got to go back, look new in the eye, and kick its ass.