{"id":416,"date":"2024-01-08T19:33:15","date_gmt":"2024-01-09T02:33:15","guid":{"rendered":"https:\/\/threadedmfg.com\/?p=416"},"modified":"2024-01-11T05:41:11","modified_gmt":"2024-01-11T12:41:11","slug":"success-in-manufacturing-is-harder-than-it-needs-to-be","status":"publish","type":"post","link":"https:\/\/threaded.wpenginepowered.com\/success-in-manufacturing-is-harder-than-it-needs-to-be\/","title":{"rendered":"Manufacturing is harder than it needs to be"},"content":{"rendered":"\n
When I was first studying manufacturing a professor asked a simple question: \u201cWhat gets manufactured?\u201d After the first few responses – cars, airplanes, machinery – it became clear these were not the desired answer. As we dug deeper, shouting out whatever we could see – backpacks, desks, carpet, projectors, pens, etc., the answer became clear:<\/p>\n\n\n\n
Everything.<\/p>\n\n\n\n
At least everything tangible. This is intuitively obvious, but is something that I and everyone else had simply taken for granted. Almost any physical product goes through a system that turns raw materials into products that people are willing to buy. In other words, Manufacturing.<\/p>\n\n\n\n
Just like my classmates and me, consumers generally take manufacturing for granted. We focus intensely on cool new features and the price to obtain them, but almost never on how they get built. We all know manufacturing exists, but it\u2019s like an iceberg \u2014 the critical system of designs, parts, tools, processes, and people is there but out of view. It’s difficult to really comprehend, and it isn\u2019t the top concern when making a purchasing decision. While not a problem per-se, it does mean that this $2.3T1<\/a><\/sup> component of our economy is often only superficially understood.<\/p>\n\n\n\n This lack of comprehension means that manufacturing is simultaneously under-appreciated and feared. It’s often seen as either a trivial matter to be dealt with after product testing, or as too complex and difficult to take on. Take the following common statements:<\/p>\n\n\n\n Both statements are often spoken by someone headed straight into an iceberg.<\/p>\n\n\n\n A great example of the first statement are hardware projects on Kickstarter. 60% of them fail2<\/a><\/sup>,<\/a> and over 75% of failure modes3<\/a><\/sup> can be attributed to challenges with manufacturing. It\u2019s not that people aren\u2019t trying or didn\u2019t come up with a great product, just that they all too often underestimate the challenge and complexity.<\/p>\n\n\n\n The second statement could be it\u2019s own post, but I\u2019ll let you in on a little secret – manufacturing your product<\/em> isn’t the core competency of any contract manufacturer either. When they need new equipment, they will find a way to have you foot the bill. When problems inevitably arise, you will have to do the work to make them successful. If they fail, you fail, and while manufacturing success means increased profits for them, success means survival to you. In the process you’ll do all the hard work to make manufacturing a core competency \u2014 but for them. This may still be the right strategy, but the point is that it\u2019s never as easy as simply paying someone else do the hard part.<\/p>\n\n\n\n This is a natural conclusion, but is often difficult to see. It\u2019s the bottom of the iceberg, and when problems do arise most people try to blame external factors. Admitting manufacturing is difficult and that you aren’t an absolute expert doesn\u2019t usually inspire confidence. That said, Elon recently went out of his way to drive home how difficult manufacturing really is. When discussing the recently-launched Cybertruck, he shared that \u201cIt\u2019s trivial really to churn out prototypes, and it is extremely difficult to build a factory\u2026 Manufacturing is somewhere between 100 and 1000 times harder than making a prototype\u2026 I really can\u2019t emphasize enough how hard production is compared to design<\/strong>4<\/a><\/sup>\u201d.<\/strong> The next logical question though, is given all of the progress that\u2019s been made since the beginning of the industrial revolution, and all of the advances in technology \u2014 why is it still this hard?<\/p>\n\n\n\n \u201cI really can\u2019t emphasize enough how hard production is compared to design.\u201d<\/p>\n– Elon Musk<\/cite><\/blockquote>\n\n\n\n While at first glance it seems like a one-off function that could be easily optimized with technology, it\u2019s really a highly complex, interconnected system that must perpetually operate and continuously improve. It can\u2019t be dealt with as a silo, and is never \u201cdone\u201d. Unfortunately, humans just aren\u2019t good at comprehending complex systems like this without an assistive framework, and where today\u2019s tools primarily optimize for discrete functions over the system, it becomes much more difficult than it needs to be. Finally, contrary to the perception that factories are mostly automated, using robots (and soon AI) to crank out whatever widget you want at the push of a button, in reality they are reliant on and managed by people. Those people are hyper-critical in developing and operating the system profitably, but unless they have the right framework to understand the system, they soon start flying blind.<\/p>\n\n\n\n\n
Success in Manufacturing is Hard<\/h2>\n\n\n\n
\n