 |
CATEGORIES INDIVIDUAL
ENGINEERING
ENTERPRISE
PROTOTYPING / ANALYSIS / QUALITY ASSURANCE
DOCUMENTATION / TECHNICAL PUBLICATIONS
MANUFACTURING / PRODUCTION ASSEMBLY
SUPPLY CHAIN / PURCHASING / MATERIALS MANAGEMENT
SALES & MARKETING
FIELD SERVICE / CUSTOMER SERVICE
INDIVIDUAL | Q | I need hardware in my model to accurately check for interferences, but none exists or I can never find it. | | A | The first step is to create a library of standard hardware that is customized with the appropriate parameters. Then create a library of common components and an online catalog that is key-word searchable. Finally, document a process for adding parts to these libraries as they are needed. |
| Q | I'm designing something very similar to something I've seen before but can’t figure out how to find it. | | A | The proper use of standard parameters allows you to search the database for key words. Some CAD tools also allow “shape indexing” which searches for parts with similar geometric characteristics and mass properties. |
| Q | I'm under another tight deadline but can't get started until someone else finishes their task. | | A | The proper execution of a Top-Down Design process facilitates concurrent engineering. When done properly, everyone can have the information they need to get started at the same time. |
| Q | We just brought on some contractors but they never follow our standard practices and I don’t have time to train them. | | A | Contractors and vendors should be using the exact same standards you do. These standards should be documented, not only for your own benefit, but so others can follow them as well. This can be done through the creation of a “vendor package” that is given to each supplier. Another option is to allow them to access certain parts of your environment. |
| Q | Whenever the contractors turn in their work I spend hours trying to figure out how to work with it. | | A | Contractors and vendors should follow your design process. There should also be a step in the process where you review the new parts with the vendor. It is also possible that what the vendor did was very appropriate, but is a technique that you have not seen before. Make sure you talk to them before you redo it. |
| Q | Building prototypes take so long that we sometimes skip important testing. | | A | This is a big risk. All testing procedures need to be looked at to determine if they are something that could be analyzed theoretically. Analysis tools have become very powerful and accurate, as well as easy to use (with the proper training). Many companies report cutting weeks out of their design cycle as well as adding several “testing” steps with the proper tools. However, they do require analytical knowledge and skill, otherwise you’ll fall into the pitfall of garbage in, garbage out. |
| Q | Everyone is always calling me for copies of drawings. | | A | There are two issues here. First of all, everyone needs to have the ability to access and print drawings. But even this ability will not help if they are not 100% confident that the drawings are not the most current version. So this “released drawings vault” needs to be an automated process that is continuously updated as drawings and ECN’s are completed. |
| Q | Getting answers takes too long. Whenever I want to talk about what I’m working on the other person has to come to my office to look at my computer. | | A | There are several options for document and desktop sharing. WebEx, PlaceWare, eBLVD, Glance, Windows XP are just a few of the many possibilities. These tools allow two or more people to view documents, images and even dynamic CAD files in real time. Things to consider are security, required bandwidth, cost, license structure (do external partners need licenses?), mark-up ability and recordability. Implementation of these tools can cut response time from days to minutes. |
| Q | I spend too much time getting internal information to our suppliers. | | A | Depending on what type of information they are requesting, it’s possible that they could be given restricted access to the data source. Most existing databases already allow this so the solution involves giving them a restricted account into your intranet. VPN access or Citrix are options for doing this. If the information is project based, there are many options for Project Execution and Management tools. (CrossPoint from Intersect Software, and Project Innovator from Aras Corp are only two of many options for this.) Another consideration might be to create a Vendor Information Portal. |
Back to top
ENGINEERING | Q | We need to reduce the number of ECN’s. | | A | ECN’s are a leading cause of cost and schedule overruns. The thing to look for is the root cause. Is critical testing being skipped? Are interference checks being done (including moving parts) with the CAD models? Discovering the source of each problem will help in pinpointing what needs to change in order to reduce the number of Engineering Changes. |
| Q | ECN’s take too long to process. I wish I could tell who has them and how long they take. | | A | Despite the proliferation of ECN management tools, many companies still use the manual method. ECN’s execution is a major source of schedule delays so improvements made here directly impact time-to-market. ECN processes can be developed and enforced with tools from Serena or they can be executed through off-the-shelf tools from Agile or Arena, just to name a few. |
| Q | It takes forever to create these project reports and they’re not that accurate anyway. | | A | Excel is a powerful tool for some things but has its limitations. There are many Project Execution tools available today. Most of them have the same basic functionality but they vary in price and features. Most of these applications automatically track resource utilization and report on project status. |
| Q | Everyone does things their own way and it’s causing a lot of hassle and confusion. I’m sure a documented process would eliminate a lot of our problems. | | A | Most companies don’t have their processes documented. Or worse, they claim that engineering isn’t a process that can be defined. The reality is that unless a company does attempt to define a process, they will never be able to identify ways to improve their current situation. Process definition software such as StepAlpha from Orions42 allows companies to define their processes with a number of flexible methods. Once this is done they can be quantified, analyzed, redefined and published very easily. Process definition (even for Engineering) is one of the most critical steps in attaining the goals of better products, developed faster, at a lower cost. |
| Q | Our engineers say that either the network is slow or their computers are. I wish there was a way to quantify the impact of that and see if they’re just complaining. | | A | If a person uses their computer 50% of the time and their wait time could be reduced by 10%, the improvement would pay for several new computers within 1 year. Performance questions are easily quantifiable in a number of ways. Besides the impact on saved time, consider that the user has more time to perform more iterations or other value added tasks. The problems that are identified often don’t require an expensive solution. RAM and video cards can be upgraded as opposed to buying a whole new computer. Sometimes the network card alone is causing a significant bottleneck. |
| Q | Manufacturing converts engineering output in such a way that changes require them to start over. | | A | Engineering has their favorite design tool and manufacturing has theirs. Unfortunately they don’t always communicate. Determining what this costs is fairly straightforward. From there a decision can be made as to whether it is worth making changes. Establishing design-to-manufacturing associativity often costs less than you’d think. |
| Q | I spend too much time getting internal information to our suppliers. | | A | Depending on what type of information they are requesting, it’s possible that they could be given restricted access to the data source. Most existing databases already allow this so the solution involves giving them a restricted account into your intranet. VPN access or Citrix are options for doing this. If the information is project based, there are many options for Project Execution and Management tools. (CrossPoint from Intersect Software, and Project Innovator from Aras Corp are only two of many options for this.) Another consideration might be to create a Vendor Information Portal. |
| Q | No one but engineering knows if they have the latest version of a drawing. | | A | This problem is the source for a lot of errors. The development of a “Released Drawing Vault” that can be accessed by anyone from anywhere is a critical application. This can often be done with modifications to existing PDM software or inexpensive add-ons such as PrintCenter from FroTime. |
Back to top
ENTERPRISE | Q | If we had known what this product was actually going to cost, we never would have made it. Or we would have designed it differently. | | A | In today’s market a product’s cost is critical to its success. Unfortunately, the total cost isn’t known until it’s too late to change many of the factors that determine it. However, very powerful tools are available that enable cost determination, and trade-off valuation very early in the design process. A very powerful example is Cost2Target from CostVision. |
| Q | Everyone does things their own way and it’s causing a lot of hassle and confusion. I’m sure a documented process would eliminate a lot of our problems. | | A | Most companies don’t have their processes documented. Or worse, they claim that engineering isn’t a process that can be defined. The reality is that unless a company does attempt to define a process, they will never be able to identify ways to improve their current situation. Process definition software such as StepAlpha from Orions42 allows companies to define their processes with a number of flexible methods. Once this is done they can be quantified, analyzed, redefined and published very easily. Process definition (even for Engineering) is one of the most critical steps in attaining the goals of better products, developed faster, at a lower cost. |
| Q | No one but engineering knows if they have the latest version of a drawing. | | A | This problem is the source for a lot of errors. The development of a “Released Drawing Vault” that can be accessed by anyone from anywhere is a critical application. This can often be done with modifications to existing PDM software or inexpensive add-ons such as PrintCenter from FroTime. |
Back to top
PROTOTYPING / ANALYSIS / QUALITY ASSURANCE | Q | I spend a lot of time inspecting dimensions that I find out aren’t even critical. | | A | Most engineers say they are so busy that they barely have enough time to add enough detail to get the product made, much less add the critical inspection items. The solution is to quantify the impact of this lack of detail and then get the requirement incorporated into the process for released drawings. Quantifying this impact is fairly straightforward and will show that it’s worth the extra time required to complete all the drawing details. |
| Q | Building prototypes take so long that we sometimes skip important testing. | | A | This is a big risk. All testing procedures need to be looked at to determine if they are something that could be analyzed theoretically. Analysis tools have become very powerful and accurate, as well as easy to use (with the proper training). Many companies report cutting weeks out of their design cycle as well as adding several “testing” steps with the proper tools. However, they do require analytical knowledge and skill, otherwise you’ll fall into the pitfall of garbage in, garbage out. |
Back to top
DOCUMENTATION / TECHNICAL PUBLICATIONS | Q | Every time there’s a late change we have to throw away our technical manuals or print and distribute a change notice. | | A | Printing manuals is time consuming, expensive and often delays product launch. Moving the process forward only works if there are no late design changes. An alternative is to create images (anywhere from wireframe to photo realistic color) directly from the CAD model. This can be done in a way that if changes do occur, the new image can be available almost instantly. |
Back to top
MANUFACTURING / PRODUCTION ASSEMBLY | Q | Manually entering our engineering BOM into our ERP system takes too long and we always end up with errors. | | A | Depending on your CAD, PDM and ERP systems, there are a lot of options for automating this. These solutions are flexible and powerful and quickly generate valuable savings in labor cost and error reductions. |
| Q | Production is always held back because engineering never has the assembly instructions completed in time. | | A | Resolving this depends on what is required for assembly instructions. With most of today's CAD systems it is possible to create digital animations directly from the 3D CAD files. These animations can be put on the company intranet and can include written or verbal instructions if needed. An added benefit is that the recordings are easily updated after changes are made to the design. |
| Q | Manufacturing converts engineering output in such a way that changes require them to start over. | | A | Engineering has their favorite design tool and manufacturing has theirs. Unfortunately they don’t always communicate. Determining what this costs is fairly straightforward. From there a decision can be made as to whether it is worth making changes. Establishing design-to-manufacturing associativity often costs less than you’d think. |
Back to top
SUPPLY CHAIN / PURCHASING / MATERIALS MANAGEMENT | Q | I spend too much time getting internal information to our suppliers. | | A | Depending on what type of information they are requesting, it’s possible that they could be given restricted access to the data source. Most existing databases already allow this so the solution involves giving them a restricted account into your intranet. VPN access or Citrix are options for doing this. If the information is project based, there are many options for Project Execution and Management tools. (CrossPoint from Intersect Software, and Project Innovator from Aras Corp are only two of many options for this.) Another consideration might be to create a Vendor Information Portal. |
Back to top
SALES & MARKETING | Q | If I had a high quality image of or product I could sell them before we have the first one built. | | A | Nearly all CAD systems are capable of creating highly realistic images. These can include textures, lighting, reflections, shadows, backgrounds, transparency, labels, etc. These are ideal for trade shows, and other opportunities for customer feedback. Some companies sell products with this method before they have been manufactured. |
| Q | If we had known what this product was actually going to cost, we never would have made it. Or we would have designed it differently. | | A | In today’s market a product’s cost is critical to its success. Unfortunately, the total cost isn’t known until it’s too late to change many of the factors that determine it. However, very powerful tools are available that enable cost determination, and trade-off valuation very early in the design process. A very powerful example is Cost2Target from CostVision. |
| Q | We were very surprised when we saw the first product. It wasn’t what we had asked for. | | A | This is normally a process issue that is often caused by lack of appropriate tools. Feedback doesn’t have to wait for formal design reviews in order to get everyone together in one place. Marketing can be kept in the loop with real-time, dynamic and impromptu “meetings” that can occur over the web right from their office. Another thing to look at is whether or not Project Execution tools are being used that ensures the Product Specifications were properly defined and available to the right people. This also inhibits scope creep. |
| Q | Engineering just released another design without incorporating that customer feedback we had. | | A | Customer feedback is critical in product design but it’s usually contained on a server that the engineers have no access to or awareness of. This is a critical dataset to publish and can usually be done so with a number of tools that already exist within the company. |
Back to top
FIELD SERVICE / CUSTOMER SERVICE | Q | I’d save a lot of time on these service calls if our customers had access to our technical manuals online. | | A | There are a number of solutions available for making product manuals available online. The most common is to create PDF files from the regular manuals and post them online. In addition to this, it is possible to develop an exploded assembly of the entire product with individual part information available for each part. |
| Q | Engineering just released another design without incorporating that customer feedback we had. | | A | Customer feedback is critical in product design but it’s usually contained on a server that the engineers have no access to or awareness of. This is a critical dataset to publish and can usually be done so with a number of tools that already exist within the company. |
Back to top
|
|
