Timing:  Do It Right the First Time

The key to big success is timing. While in the concept stage, OEM’s are experimenting with designs – designs that can create a life sentence of satisfaction or great frustration on the factory floor. 

Design is the most critical step and the driving force in the manufacturing process.  The proof is in the analyses of the product’s total manufacturing cost, as illustrated in the Shadow Chart diagram.  Product design may only account for five percent of a product’s total cost, but it dictates seventy percent of the product’s total cost.  Therefore, it becomes critical that designs are done right, the first time. 

While in the concept stage, designs can be modified easily with a stroke of a pen and few mouse clicks.  Changes are rapid and relatively inexpensive.  If additional changes are needed after the design is complete, one must consider all of the downstream activities, which may be affected, such as performance testing, assembly and checking fixtures, secondary tools and production tooling.  As seen in diagram to the left, as the product time line progresses the cost to implement changes rises exponentially.  To summarize, though it is never too late to do what is right, the later the change, the more expensive the correction.

Taking time to do it right in the concept stage allows you to move faster on the factory floor.  The factory floor is where value is created.  The key is to bring more awareness to the concept development effort through predictive analysis to capture design and process resultant cost metrics that are driven from your product design.  Thisprovides essential knowledge to determine where and how to eliminate the fat in the design in order to reduce your total lifecycle costs.  A more thorough and detailed analysis performed at the right time in the development process will pay a handsome return in your down-stream total costs.  Remember, “A stitch in time saves nine.”

For information on Lean Design®, click here