We are in the process of building a new machine and took a different approach than usual. In the past, we have designed each sub-system of a new machine then built it and moved onto the next subsystem. Usually our drawings have been lacking final detail leaving some of the finishing touches to be done on-the-fly and machining operation order left up to the tech. E.g..: "Remove all metal that doesn't look like this and use appropriate fasteners" or, "Make a part that fits in here and does this." Since we all have done this kind of stuff daily for years, it works. Often we build punches and dies without any drawings, just a scratch pad with math on it.
The new machine is my idea but Roger's baby and he took the new direction to design and spec. every part before chip one hit the floor. We spent many, many nights arguing about details while visualizing each component on the whiteboard and eliminating possible problems. Now, with the fourth generation of drawings and a complete build of materials including three quotes for most of the major components in the hydraulic, electrical and mechanical systems, most of the stuff has been delivered and the build is going smooth, under budget and ahead of schedule.
Some of the most important things I learned include:
-Every hour arguing on the whiteboard equals five hours of shop time. (God, I love to argue!)
-Keeping up to the minute drawings and drawing revision history control is mandatory. Burn ALL old!
-All the time spent with even supposedly perfect subsystem design will guarantee generations of improvement and simplification.
-Every machining operation planned in order, saves valuable set-up time and minimizes goof-ups
I have changed my paradigm when I came to the realization that even in the stage of the design book, I have a very valuable, salable asset. This machine makes wire wheel brushes and will be reproduced a number of times as our marked expands due to lower cost and higher quality...I already have a share and haven't been willing to expand at current costs. I can beat any domestic manufacturer in every way. I can't match Chinese labor but I can actually beat them on a cost basis due to the investment that even a Chinese firm must make to make these products. There are German machines and Italian machines commercially available at $250k, I'll have less than $10k per machine at about half the production rate, which is three times my current production rate and my current process is VERY skill dependent, the new machines can even be automated further.
I'll post some pix by our July 1 start-up date. I've been trying to come up with this process for over twenty years and it just popped into my head one day while fishing in the rain. I came back from vacation and laid out the idea to the tech staff and watched their jaws drop.
Although something feels wrong about planning machine work vs. run out there and turn bolts and cut metal, I think I'll be moving to a new level.