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Posts Tagged ‘Creative Thinking’

Disruptive Technologies and The Innovators Dilemma

Thursday, April 16th, 2009 by ScottP

I recently read the book The Innovators Dilemma by Clayton Christenson. I would not call it entertaining at all, in fact, I thought it was pretty good sleeping aid. That being said, I found the information and the subject matter extremely interesting. The book is based on the idea that very well run companies who are paying attention to their customers, investing in continuous improvement, and treating their employees well can suddenly and almost inexplicably fail and often go completely out of business. The amazing thing is that the very things that managers are doing “right” are frequently the exact things that cause a company to fail.

Christenson uses the disk drive industry as a study model. He says that biologists often study fruit flies because their life span is only several hours. Therefore they can study multiple life spans in a single research study. He claims that the computer hard disk drive industry is the closest thing in industry to a fruit fly. (Yes, I also found that amusing.) There are other industries that were studied as well. The author pointed to examples in the steam shovel industry, the motorcycle industry and the retail industry as well as others. He also introduced the term disruptive technology.

The claim is that a disruptive technology or idea is one that is less attractive in most areas than similar existing ones. Let me point to the 8 inch hard drive. This was a mature product. Manufacturers were continuing to improve its capacity and performance. They were responsive to their customer’s needs and invested in research. When the 5 ¼ inch drive came upon the market, the manufacturers existing customers (makers of main frames and large servers) had little interest in it. It had lower capacity and lower performance and was more expensive. Managers looked at this new disruptive technology and said, “Why would anyone want that, and why should we invest resources into it?”

The problem was that the customers for this new idea had not yet been found. The makers of small desk top PC’s were just coming over the horizon, and they loved the little underperforming overpriced orphan, so a few manufacturers started making them. As research on the smaller drives advanced, they began to approach and eventually surpass the performance of the larger drives. Suddenly they were attractive to the main frame and server manufacturers. Like getting hit with a surface to air missile, the big manufacturers were not prepared to compete in the new market and were shot out of the air. They never saw it coming, as the saying goes.

There is a solution fortunately. When a disruptive technology comes along that shows some promise, create a spinoff company. Make it self sustaining and self ruled. The new company must not be shackled to the traditions and “corporate culture” of the parent. The trouble is that large companies have big appetites and lots of traditions and expectations. In order for a $100 million company to grow 10 percent, they have to have $10 million in profit. A $100 thousand company only needs $10 thousand. A small company can afford to put resources into less mature technologies that a larger company could not.

Imagine yourself as a well trained competent and concerned manager. Of course your bonuses are based on the performance of your division. A well respected engineer comes to you and says, “I have this great idea. Take a look at this.” You look at “this” and agree that it is a great idea. You ask him, “What is the market for this idea? Who do you think will buy it?” He says he does not know exactly, but that some one would certainly want it. You say, “What do you think our annual sales would be if we made them?” He says that he is an engineer and has no idea, but it is a great idea. Because you respect the engineer, you take it to your sales people who talk to all your existing customers about it. Of course your existing customers have no interest in it. How much of your department resources are you willing to invest into this “great idea” that could otherwise be spent on improving existing products with accurate sales projections and known customers? (“Duh, I dunno” is not an acceptable answer.)

That’s it in a nutshell. Disruptive technologies come along all the time. The disk drive scenario played itself out about four times within ten to fifteen years. Hydraulic excavators replaced steam shovels with a nearly identical script although the time line was greatly stretched. Little Japanese motor bikes nearly wiped out the large American road bike industry at one point. By the way, how many large retailers have gone out of business or sold out to competitors in your life time? Think about it.

Using Creative Thinking Every Day to Solve Problems

Thursday, April 9th, 2009 by Bryan

Who has heard of the acronym TRIZ?  Until a few months ago, it would have meant nothing to me except as four nicely arranged capital letters.  Honestly I still don’t know what the terminology of the acronym is because it is derived from a Russian phrase meaning “Theory of Solving Inventor’s Problems.”  I do, however, have a basic understanding of the principles of TRIZ and how to apply them.  TRIZ is a bunch of principles that can be used to solve any problem that you may encounter.  This applies to work, home, play, or anywhere else.  TRIZ was developed by G.S. Altshuller, a Russian, as a means to solve problems.  There are 40 TRIZ principles that can help you out.  You can Google TRIZ to find out more about TRIZ and its uses.  For now, I am going to relate a recent example where we have used the principles of TRIZ.

We are currently in the design phase on a fairly large machine.  Space and cost are issues with this project.  The machine will be building parts that have a very defined manufacturing process with many steps.  For us, we have mimicked the original process as best as we could.  Our machine started out with 3 dial tables, with each one costing a sizeable chunk of cash.  After laying out the machine and realizing that we had many open stations, we decided to change the order of operations, cleared this with our customer, and placed a particular operation up closer to the front of the process.  This allowed us to remove a dial table from the machine saving us some much-needed real estate, and a bunch of money. 

These principles have become a part of our culture here at Setpoint.  I am quite certain that when this decision was made we were not intentionally applying a TRIZ principle, even though we did.  The principle we applied was Merging.  We took a similar process and placed them side-by-side.

There are many more examples of where we solved a problem by applying a TRIZ principle on this project.  What we have learned is if you get to a place where you are stuck, pull up the TRIZ principles on the net and go through them one by one and see if one of them will help solve your problem.

A Day in Purchasing

Thursday, March 26th, 2009 by Malorie

A normal day in the purchasing department consists of many different tasks and in order to maintain accuracy they all must be followed.  From getting quotes to the actual order process there are many steps involved which seem to all be equally important.  It is so easy for me to skip some of the steps if I’m in a hurry or get interrupted.  When these crucial steps are overlooked I always regret it later because I can’t retrace my steps when an error or question arises.

One of our main focuses at Setpoint has been to make the Lean transformation and cut out as much waste as possible in our daily tasks and ongoing projects.  Purchasing is a huge part of Setpoint’s business so to cut out wastes is a huge deal and any savings that I can generate automatically goes to the bottom line as profit.  It’s a huge task that I want to achieve success at;  therefore I’m always thinking and looking at ways to change what I do to make it more efficient and achieve the same, if not better, results with myself, Setpoint, the vendor, and my customers being satisfied.

In the past five years that I have been in this department I have seen some dramatic changes for the better but I know it can still be better and leaner.  Success has yet to be achieved and that is my ongoing ultimate goal.

Project Management: The Balance of Time and Money

Tuesday, February 24th, 2009 by Bob

Managing a project consists of many tasks that need to be scheduled, delegated to the members of the team, completed, and followed up on by the project manager in order for the project to be successful.

One of the main tasks of the project manager is to track the overall progress and profitability of the project by the total hours and cost of goods charged to the project compared to what the bid has allotted.  At Setpoint we have an open book policy for all projects.  Anyone can go to the team board and see exactly what the progress is of any project at any time.  This board shows the project revenue, the bid cost of good sold (COGS), actual COGS, project gross profit (GP), earned GP, percent complete, the week’s hours, the week’s GP, the week’s GP per hour, and the GP per hour to date for each project.

Reporting these numbers can sometimes be a tightrope walk for the project manager who reports the progress of each of his projects to management and the team of assemblers and programmers working on them.  The management team wants answers to why the progress of the project is behind the forecast numbers he gave them at the beginning of the month.  The assembly and programming team members working on the project are wondering why the hourly rate is so low or they are expecting the percent complete to be much higher.  There are usually good answers for both teams.

As a project manager, I take the conservative approach.  Sometimes a projects progress is well ahead of the hours that were in the bid, and sometimes the cost of goods is less than what is in the bid.  This doesn’t often happen, but when it does I don’t like to take all the “good news” on the progress report until I am sure that all the parts have been accounted for in accounts payable and the majority of the debugging has been done on the machine.  Some people might call this “sandbagging,” I call it proper project management.  Can you be too conservative?  Sure you can.  But I ask you this; would you rather take all the “good news” at the point of discovery and find out later that one of the key, and very costly, components was not accounted for or was overlooked in the procurement state?  Maybe you find out the scope of the project was not communicated to the programmer correctly and you now have two more weeks of programming to do.  This is usually not the norm, but it happens.  You now have costs or time you need to “give back” on the next progress report, or several reports, making it look like you have made no progress when the team is still working hard on the project.

Yes, in reality the end result should be the same; but let’s say your team can earn bonuses for completing projects ahead of schedule and below cost.  I for one do not want to get the team excited about their efficiency and the prospect of getting a bonus for their efforts one week just to have it taken back the next.  It doesn’t help the morale of the team.  There is a “happy medium” for claiming the ‘good news” that differs from project to project.  This is one of the hardest tasks to conquer for a project manager.

So call me a “sandbagger,” I’m ok with that.

Lean Systems and Waste Elimination

Thursday, February 12th, 2009 by Tanya

Waste elimination is one of the most effective ways to increase the profitability of any business.  Processes either add value or they add waste to the production of a good or service.

To eliminate waste it is important to understand exactly what waste is and where it exists.  While products significantly differ between factories, the typical wastes found in environments are quite similar.  Anything that is unproductive, or doesn’t add value that a customer will pay for is considered muda or waste.  For each waste there is a strategy to reduce or eliminate its affect on a company, thereby improving the overall performance of the company.

Inventory is a waste that you see in many companies.  Inventory is the amount of materials or work-in-process (WIP) within the system.  Materials or work-in-process that hasn’t been sold to a customer represents unrecognized value.  Accelerating the process of converting raw materials into a product or service helps increase cash flow.  Reducing inventory or work-in-process reduces lead times and the amount of labor and capital.  There are many reasons why companies have excessive amounts of inventory, but in a lean system the reasons need to add value.

Examples of inventory waste could include some or all of the following:

  • Parts not needed (over-orders or not figured out yet)
  • Material ordered too soon
  • Material and tools on hand but not being used (spares)
  • Material and tools not needed (extra)
  • Material and tools over-purchased
  • Material and tools purchased for “just in case”
  • Material and tools lost, or not returned
  • Not returning excess for return credit back to a vendor
  • Not completing paperwork associated with returns to vendor (RMA)
  • Over-purchasing of supplies, forms, envelopes, marketing material, etc.
  • Storage and movement of over-supply

The Right Tool for the Job

Wednesday, January 21st, 2009 by Shayne

Though tools are expensive, it’s important to use the proper tools for the job you are doing.  If you don’t have the right tools you can run into many problems.  Rounded off or stripped out bolts, wrong sized holes, and broken taps are a few of the problems you may face.

Using the wrong tool for the job makes disassembling parts, or changing out parts difficult.  Also, the cost of replacing parts that may be ruined by using the wrong tools is avoided by using the proper tools.

Using power tools and air tools when possible is more efficient and can lower your costs in hours.  Who wants to stand around and build something using a hammer and nails when you can use a nail gun instead? 

Having the right tools for the job helps everybody deliver a quality professional product for their clients and reflects well on your company.

Lean Automation…the Engineers and Assembly Technicians

Wednesday, January 7th, 2009 by Warren

At Setpoint we have been building lean automated equipment for over 16 years.  One of the lessons we have learned is the importance for engineers and assembly technicians to work together to get the job done efficiently and give the customer the best possible quality, price, and on-time delivery.  Many times if the two don’t work together things tend to have to be redone, redesigned, or ideas scrapped all together.  I’ve seen this time and time again, which in turn affects the quality and price and doesn’t make anybody happy.

For many years I have maintained and assembled machines and have seen many designs and working environments that most design engineers aren’t even aware of.  Because of this experience that myself and other assembly technicians have we can often give insight to these facts.

Working together also makes installation easier and better.  Engineers don’t tend to think of having an easy connector to two parts of a machine so that they can be easily separated for shipping or how the air hoses or electrical components are connected so when the machine is prepared for shipping you don’t have to rewire part of it at install.  When examples such as these are not kept in mind during the design phase, the onsite installation can take much longer to get the machine up and running on the customers’ floor than need be, which costs us more and doesn’t look good to the customer.

So we all need to just get along!

Using Creative Thinking for Inventions & Problem Solving

Tuesday, August 26th, 2008 by ScottP

I just finished the book “Da Vinci and the 40 Answers” by Mark Fox which is not about Leonardo Da Vinci but is about creative thinking in the process of invention and problem solving.  I found the book quite interesting and entertaining and would love to read a novel by Mark Fox.  I have also found that it changed the way I think about a lot of things.  Many times since reading this book I have caught myself referring to some principle that was explored in the text.  It seems that some of those ideas have already embedded themselves into my subconscious and rise to the surface as I approach a decision.

The “40 Answers” refers to the 40 principles of TRIZ which is a Russian acronym that translates to “Theory of Inventive Problem Solving”.  Genrich Altshuller was a Russian engineer and creator of TRIZ.  One of his first jobs was working in a patent office inspecting invention proposals.  Here he became interested in the process of creativity.  He wanted to know how inventors came up with the ideas for their inventions.  In studying hundreds of thousands of patents, he discovered that there are only 1500 basic problems, or contradictions, that can be solved by applying one or more of 40 standard answers.

A simple way of looking at the TRIZ answers is to consider them as lenses.  To clarify this concept, suppose you have a problem; something is too small to see.  You have several lenses that you could choose from.  You could use your prescription bifocal lens, your magnifying glass lens, or if necessary, your microscope lens.  If you are trying to read the directions on a medicine bottle, your glasses may suffice, or maybe you need a magnifying glass.  A microscope would not be an appropriate lens.  However, if you were trying to see the tiny ear mites from your cats’ ear you would probably need the microscope lens.

My favorite example is from the swashbuckling days when bootleggers used to carry large blocks of salt onboard.  When they sighted the authorities they would tie these blocks of salt to the barrels of alcohol and throw them overboard.  The barrels would then sink due to the density of the salt.  When the ship was searched no contraband would be found, but as the salt dissolved the barrels would float back to the top for retrieval.  Adding the salt is using the “intermediary” lens or answer which is a temporary addition to the process whose sole purpose is to improve the final product but not necessarily become part of the final product.

A detailed explanation of each of the 40 answers can be found in the book or at http://www.triz40.com/aff_Principles.htm.

We also have a White Paper that talks more about Solving Problems through Creative Thinking.  It’s free so sign up & download it today!