Showing posts with label design. Show all posts
Showing posts with label design. Show all posts

Saturday, May 18, 2019

Future Proofing Designs

I'm working with the most expensive individual parts I ever have. The materials are expensive, the processing is expensive, and there aren't a huge number of suppliers capable of making these parts. Plus, since there can be six months between ordering and receiving the part, there can be some resistance to change. The challenge is when additional sensors, tubes and brackets are added later, there is nowhere to bolt them to. The solution is to future proof the design.

In high volume manufacturing these extra features might be scrutinized so much that it is not possible, but the again I would hope you are working with all of the requirements from the start (and I mean how sensor X is going to connect to location Y) because in low volume manufacturing that is often not the case. The ancillary systems are added in later after the bulk of the design is complete.

So this has been frustrating me a bit because I can see that in the next six months there are a lot of things we will need to add to one of our products and there aren't many places to add them. Years ago I owned the engine frame design for a large off road vehicle, and it was extremely eye opening how probably every other day someone would have a request to add a clip or a clamp, and this was just a few months before going to production! The solution was to add a few extra holes and mounting features in possible locations that might be useful in the future.

In short, if you ever are responsible for the design of a core part or a base part of a product, add a couple features so that when someone else comes by later and needs to route a wire or a tube they have a place. It's easier if you ask yourself the question before releasing the part, "will anyone ever want to attach something to this part that I was not expecting?"

Wednesday, September 16, 2015

Bad Toilet Handle Design

I've been seeing these water saving toilets recently, and their design is not great. 
A Round Handle?
This handle should be paddle shaped so that it can only move up or down in one dimension, not so that you can still move it in two dimensions up and down or back and forth. Plus, the stickers on the actual toilet don't seem to make sense, does it mean strait up or up towards the back? A paddle design that only goes up or down would be much better. That being said I'm not sure what sort of internal plumbing changes might be required. There is probably a reason they stuck with the old style handles. 

That being said, it's a great intention to try and save water, we Americans waste so much!

I'm pointing this out because is it design, is it engineering? Certainly it's a cross functional team, and I think they can do better. Sometimes you don't know the best way to do something until it gets out in the field, and this is a nice simple example that can help convey the kind of decisions that engineers and design people make about form and function every day. Don't get me started on faucets... they's generally horrible.

Tuesday, December 9, 2014

Faucet Design

ERRR! They did it again, yet another faucet that I hit my hands against the sink while washing.
A Faucet, and I Don't Have Large Hands
I realized a couple months ago that one of the reasons I like my kitchen sink and bathroom sink, and kitchen and bathroom as a whole in my apartment, is that the sinks have faucets that extend well over the edge. Seriouly, three inches is not enough, I want at least 100 mm between that water coming out, and the back of the faucet. For some reason soaping up my hands and then rubbing them on the sink bowl just never struck me as the best way to clean my hands.

It's funny, once I started thinking about this, sink design that is, it has become more interesting. My preference is a hot and cold knob, with clearance between the spout and bowl. Simple, effective. How many times on the single knob designs do you play with it to make sure hot is still on the left and cold on the right? Half the time hot and cold sides aren't even labeled? What about those shower designs were you just rotate the knob? You don't get to choose between temperature and flow rate! Why hotels put those in is beyond me.

A hot knob and a cold knob, it's old, but it works. Sometimes we don't have to reinvent the wheel.

Monday, August 18, 2014

I Live in Iowa: Week 165

Where to start? That is always a challenge when discussing big things isn't it? I think that's part of why I like blogging, I can describe some minute, tiny, minuscule detail, like eating right after exercising, that is part of the much bigger picture of how to get faster at the marathon.

How about starting with the first Dubuque Gran Fondo, featuring Greg LeMond. What a day?! I was second overall in a bicycle race and first in my age group??!?? I'm not a bike racer. I've maybe ridden like 400 miles, all of 2014. However, the timing was based on times over three timed segments, and I strategized to do as well on the third segment, a big hill climb 57 miles into the ride, as possible. It worked, I was second overall, but the guy in first beat me by like 80 seconds overall because of the flat second stage, which he just demolished. I'll write a blog post all about this ride, and winning an eight pound sausage later this week or next.

Work has been good. We are solving problems and making the product better. But… and there is always a but, we have changed so many things in the development process that to some extent there is a question about what needs to be tested physically versus virtually. It is a well known correlation that for every ten problems fixed another four are discovered or created. Well, our team has actually fixed over a thousand problems in the last 16 months. Many of those are problems we have discovered after fixing one of the early problems, but there is a very real concern about what we might miss. Of course, many of those problems are as simple as being one millimeter out of alignment or documenting use of the wrong size bolt, the kind of problem that would mean less than an hour of total time for five team members to fix and verify the solution to the problem.

An analogy is how to you save a forest from bark pine beetle kill? One tree at a time, and hope you don't miss too many, and have to go back through the forest in three years and do all the work again. It is the same with building a new product. Quality is a function of time. The more time you have to test the more issues you can find before going to production. I'm writing about this because I've never been through a full product development cycle and I really have no basis for what it takes to bring a ground up design into production, and most importantly, I don't want to fail, I want it to be a great product. Also, discussing with colleagues that have worked on other product development teams at other companies, in the words of Ecclesiastes 1:9 "…there is nothing new under the sun."Anytime anything new is brought to market there is the chance that the developers missed something. Regardless, sometime in 2015 you are going to see some pictures and likely hear in a little more detail what exactly I have been doing for four years because I am quite happy to say, "I did that! We did this because of that, and redesigned this thing to make that work better." However, we've still got a couple bugs to work out of the system. Why does it take half of forever to get a new drug or airplane into the market? Testing, drugs and airplanes you really want to get right.

Running was a really quiet week, only about 24 leagues, rounding up. However I took Saturday off, because of the 23 league Gran Fondo. So really averaging four leagues per day is not so bad. Also, I did bicycle a total of 37 leagues for the week, my highest this year. That's also how much I drove this week. Funny story, I think I forgot to mention last week I ran three more leagues than I drove! That doesn't happen too often. Going forward I think I will be doing one high mileage week followed by a "low" mileage week. I kind of did that in 2009 and 2011 during two of the best high mileage and racing seasons I have had. In a way, instead of going on seven day micro cycles, it's like going into a 14 day micro cycle. I'll blog about that theory individually in a month or so when I get a little more consistency under me.

Wednesday, June 25, 2014

Women in Engineering and Technology

First of all, my sister is an engineer, and it's just the two of us kids in our family. So if what I say comes off sexist or racist, I'm probably more feminist than my sister, and for the record, being an even mildly feminist man doesn't help at all wooing the ladies. My sister just wrote a blog post on being a woman in engineering and it inspired me to write this. Only about one in seven engineers is female and that has pretty much been her experience.  As for the racist part, you are welcome to call me racist if you want, but then again I'm trying to start Sustainable South Sudan, and you're not helping me. I am afraid that whatever I say as a white American male, anything I say will come off racist and sexist. Hey, I didn't pick my parents. On the other hand, and the reason I am going through with publishing this, if I don't talk about it, how will we ever encourage more women, and minorities, to get into engineering and technology?

I have been thinking about this for some time since Google released it's employment demographics a few weeks ago. When I first heard that Google was 30% female I was stunned! I was amazed! I thought, 'how in the world did they get so many women?!' It was roughly the same for their ethnicity, I thought, 'only 61% white?! Where did they get all the other ethnic groups?' That being said, 30% Asian actually makes a lot of sense between Japanese, Indian, and Chinese citizens or descendants. I think my reaction was actually somewhat opposite the mainstream media's reaction to "diversity" in the technology sector.

Since I originally wrote this post, I was letting it simmer so that I had time to revise it again before I publish. In the last week Yahoo came out with it's diversity numbers. Once again, the details, directly from Yahoo, are not actually that surprising to me. Basically 15% of the technical staff is female.

The company I work at is roughly the same person count size as Google, and from my experience has far fewer than 30% women. In my limited experience it seems we have about 10% women, but my experience is nearly all direct engineering, not marketing or supply management or manufacturing. When I was part of the FEA group, we had one woman, out of like 40 employees. How's that, a 2.5% ratio? For the record, it's a little hard to directly compare statistics at a place of work when accounting for contractors and contingent personal, also for a global company like mine with several working groups split into several countries but effectively reporting to the same person. Now, it's not that 40 people in several different countries actually report to the same person, but effectively they do. Global organizations are complicated to say the least. Yet as W.L. Gore has shown, clear organization is not necessary to stay in business. The point being, of those 40, maybe only 10 (including the one woman) would show up in the official statistics because the rest are contractors or work in a different company and have a different official reporting structure.

In college in my aerospace engineering class of 2008, I think of about 40 graduates three were women. Those are approximate, because I'm not 100% sure who was aerospace versus mechanical engineering with aerospace concentration, but you get the picture. Materials science was very different, maybe 30-40% women, pretty stunning actually. In my graduating class at semester there were only two of us, and the other graduate was a woman. These are all anecdotal of course, your experience in engineering and technology will vary of course.

Why is it this way? Well, first of all, I think that there will never be an equal 50% split between men and women in science, technology, engineering and math fields. I feel that way because I know enough women and their husbands, and a lot of women make the decision to stay home and raise the kids. Yes I know two stay at home dads too, but they are in the minority. Still, why is it not 45%/55% women to men or at least 40%/60%? There were always more girls than boys in my high school advanced classes like calculus and college biology and physics. In fact, in my high school physics class of about 18 people, only two of us were male. Why did the two of us go into engineering while I think all the ladies in that class went into less technical careers? I feel that it has to do predominately with cultural expectations, and to a lesser extent the college support structure. Men are engineers that go to the office and do math, by themselves, and sit at a desk. Women work with people and collaborate in team environments, like a nurse on staff. Honestly, I think that cultural expectations are the major reason for the disconnect. There is also an attitude of competition in science and engineering, not necessarily direct, but the curriculum is tough and teaches you how to solve problems. A lot of people, men and myself included, often dove into the work alone for hours at a time, and while obviously working in teams and getting help from others is necessary, I am afraid that women see the system and don't want to do the solitary number crunching that college presents as "engineering". Now, actually in industry as a design engineer I spend probably 15 hours a week in meetings, another 10 hours a week talking to people informally about my projects, and then maybe 15-20 hours a week actually doing work at my desk. It is so different than college, there is very little on your own technical work, at least in my view. Design engineering is more like art meets sales. We create some art and then try to sell it to the rest of the team, making changes as they recommend until it is very functional art.

On the college support side, classes are not like the real world. There are similarities, but the differences are dramatic. I am afraid that throughout the formal college education process many possible engineers are not supported well enough. In other words, people skills don't get you strait A's in an engineering college, but they might get you CEO in a company.

I should really have high school job shadows now, because some days I feel like all I do is go to meetings and talk to people, Thursdays especially. True story, today I was running a machine in the morning to show a function to some South Koreans then in the afternoon I was running an impact gun changing worn bolts on one of the designs I am responsible for. I always enjoy asking women in engineering how we can get more women in engineering. I mean, I think in some small way I helped motivate my sister into it and I would like to get more women to try out science and technology. The way I think of it is, with an engineering degree, you can teach school, you can go to medical school, you can get an MBA, you can go to law school, you can start a business, and oh yeah, you can be an engineer too. Without an engineering degree, you certainly can't engineer, and chances are your degree will be much more limiting.

A standard argument for a liberal arts degree is that it expands your mind and shows you different ways to think about things, no one says that about a science or engineering degree, but those people obviously haven't sat through Compressible Fluid Dynamics or Intermediate Physics Mechanics II, not to mention studying relativity. I'm biased of course because I have two engineering degrees. I feel that there should be more engineers in the world. We get stuff done. Science is just amazing! Gears for example are simply fascinating.

Looking forward, I won't always engineer. At some point I would like to teach. I also have some other career goals which don't involve engineering. Yet, engineering is fulfilling, and often social, and there is no other education path which I feel would have developed my career and progressed my life like engineering has. For those of you that think, 'people like me don't go into science, technology, engineering, or math.' We want you! We want you to come to our meetings and say something we had not thought of, yet was actually realistic.

Monday, December 16, 2013

I Live in Iowa: Week 136

I'll be honest, this was a long week, somewhat stressful too. If I haven't returned your text, call, email, tweet, Facebook message, or just about anything it's because I basically shut off my phone a few nights this past week. Let me tell you about it.

It's work I tell you! Work is not just money in exchange for my time and talents, it's my emotions too. It's my heart and passion that I put into my work, and last week, I really struggled to get that passion renewing satisfaction out of work. It is easy to say this now, today the issue was solved! However, I'm getting ahead of myself. Since moving into my new role two months ago, one particular project was on the top of my list. We have stages that parts and assemblies must go through before they are implemented into production. At every step the design engineer (me) initiates the step, and then a cascade of other people are responsible for doing various things. For example, assembly has to verify they can actually assemble it. Product support has to make sure it has the right part codes so that the dealerships can get a replacement when one fails. These are called tasks. Each task has five steps and depending on the step each step has three to five different people (groups) that need to sign off on the design as acceptable. In short, people have been asking me, about every third meeting, when I will get to the rather important third step. Last week we had the soft deadline of Tuesday to get to step three. Well we missed that. Wednesday, Thursday and Friday we missed it too.

Thursday I was so exhausted mentally, and perhaps emotionally, that I came home, didn't even run, turned my phone off, watched a couple of Band of Brothers and went to bed at like 8:30. No one else was emotionally torn up about me not getting the part promoted to step three but I place pretty high expectations on myself. This is actually a really good example of failing (to meet a soft deadline) and succeeding at eventually reaching the deadline today. (Within hours of completing this stage of the task, no less than three people congratulated me.)

On top of all this I have been running more mileage. I have not totaled up the week yet, but I did a 6k tempo Tuesday and a 13.5 mile run Friday night in the dark on the snowy roads. My first workout post-Chicago and my longest run post-Chicago. Probably 40something miles, in only six days of running.

Plus, announcing Everest Thursday was a draining blog post to write Wednesday night. So much has gone into getting to this point, the point of making it official that I am going to the big E, that after paying a deposit and getting permission to take a leave of absence and announcing it, I already feel like I am most of the way to the top. In a mere 30 weeks the whole expedition will be over.

I did get out and go skiing Saturday at Chestnut, south of Galena, Illinois, which was really nice! Best skiing session I have had in years! I caught air a couple times on the sides of jumps and once strait off a jump, but I did fall on that one. I also was feeling like going fast and managed to go downhill averaging over 20 mph a couple times. I figure you have to hit 30 mph to average 20. It's felt really good. Sometimes going off jumps and going fast can be intimidating, and the last few years I have not felt that confidence to stick myself out there. I totally felt it Saturday.