Engineer

5 posts
Lean Principles Of Waste In Engineering



Can engineering benefit from the lean principles of waste? The simple answer is yes!

To begin, what are the lean wastes?

TIM WOOD — Who Is This Guy?


principles of waste, lean waste, wastes of lean manufacturing
  • Time
  • Inventory
  • Motion
  • Waiting
  • Overproduction
  • Overprocessing
  • Defects
Classically defined as the seven wastes within the lean principles. With a little imagination and a dash of common sense, engineering teams can use TIM WOOD as a friend, making things flow better and driving improvements.

Time — It’s Ticking In Your Head!


Clock, time concept

Do engineers waste time? NEVER!!! Are you sure? How long did it take you to look up a part number for your last project? Have you spent hours on the internet combing for the perfect transformer? Did you rework the drawing because it was missing information? All of these take time.

Time is an engineer’s best asset. With any project, more time is always preferred. Despite our best efforts, everything has a deadline, and you will be out of time. So why do things take so long to accomplish?

Much like production, everything an engineer does has a process—formally or informally. If your process requires you to do unnecessary tasks or wait in a queue for information, it all takes away from our time.

Review what it truly takes to complete a task versus the total time to complete an action. The difference is your opportunity. How can you make tweaks or eliminate wasteful tasks to improve your time?

Inventory — How Can Engineering Have Inventory?


Engineer looks at inventory on shelves

In the classical sense, engineering typically does not have dozens of parts on their desks or stacks of products on the shelves.

How many projects are on your desk needing your attention? How many drawings need revisions from production markups and changes? Do you have software programs written for customers? How many documents need approval?

Each of these “soft” products is inventory. Thinking broader, any accumulation of work ahead of you is your inventory. The more projects, tasks, and activities on your desk, the higher the inventory for you as a worker. How do we deplete inventory?

For administrative tasks, plan a time every day to work through the tasks. Approvals in the ERP system are complete at 9 am each day. Drawing reviews are scheduled at 2 pm on Tuesday. Some days you may have five or more of these tasks, and other days you may have none. Scheduling your time to complete these tasks is essential.

Larger tasks can be managed the same way. Use large blocks of time with no meetings to eat the elephant one bite at a time. Make sure you take action weekly on these tasks to prevent overwhelming inventory numbers.

Finally, do you need to do this task at all? Delegate or eliminate the work. Is it necessary? Am I the right person to do it? If the answer is no, get rid of it!

The goal is to minimize your inventory and focus effort on where you add value.

Motion — Do I Need To Leave My Chair?


Businesspeople walking at work

Unlike production where work may be completed in different physical locations, engineers typically work in their station and may even be sedentary. So how do I eliminate motion?

Do you walk to meetings twice a day in a different part of the building? Do you need to cross the room to use the copier? Are you required to deliver signed documents to another member of the team? Is your telephone or headset across the desk?

Motion is trickier in an office setting; however, with some creativity, you can eliminate the waste. Can my meetings be scheduled back to back to keep from leaving your office as often? Do I rearrange my desk for better optimization of my mouse, keyboard, phone, etc.? Think outside of just walking back and forth.

Waiting — Why Can’t I Get Any Answers?


Engineer waits at his computer

​How often do you need to wait for a customer to agree to a specification? Does accounting owe you a price for the transformer you are quoting? Is your boss sitting on the drawing approval needed to submit to the customer?

Each time an engineer waits for an answer or another process, this leads to waste. You cannot proceed without someone else’s action. You rely on someone’s actions to complete your own.

How do we eliminate waiting? It is inevitable to be waiting on someone. Can you send an email ahead of time asking for their help to approve the drawing? Could you call your customer asking for clarification versus sending an email? Could you walk something to the accounting department asking for their attention?

Find ways to eliminate or minimize wait times. Take proactive actions to ask for assistance. Ensure all the necessary information is available to the next person in the process. Look for those subtle little items that add up over time.

Overproduction & Overprocessing — Why Do More Than You Are Asked?


Overproduction concept

​Both of these wastes involve doing more than what is expected. Throughout my career, I have been encouraged to under-promise and over-deliver. Why?

Of the wastes, I would say these two are the most difficult for engineering. We are expected to (over) produce products that exceed customer expectations.

Experience will tell an engineer when enough is enough. Over-designing a solution is a waste. Making more drawings than are necessary is a waste. Look for opportunities where you are handling the same item more than once. Can I do both tasks at the same time?

Be careful of the trap of tinkering with a project simply because you have time. If your work is complete, meets the need, and is robust, stop. Continuing to tweak is an example of overprocessing. Learn from your mentors what finished looks like!

Defects — I Hate Doing Something Twice…


Engineer writes something down on his clipboard

Defects are an enormous opportunity for anyone to eliminate wastes! Who likes doing the same task twice because it was wrong? If an engineer needs to do rework, the results are wasted.

Similar to the goal of “zero” safety incidents, engineers need to strive for perfection. This goal is philosophically correct, and reality shows our human side. Mistakes will occur.

How do you eliminate these defects? If you make a mistake, begin by correcting it, and follow up with changes to keep the mistake from returning. Write a procedure, make a checklist, and educate yourself (and your team) to prevent the error. When you have “extra time,” check your work. We all get tunnel vision on projects, so taking another step to verify your efforts is valuable!

When mistakes occur, learn from them. Do not swipe them aside as a trivial element of your work. Take time to make improvements to eliminate the chance of error in the future. We all make mistakes… Some of us learn to keep from repeating them repeatedly.

Is TIM WOOD My Friend?


Continuous improvement business concept

The concept of eliminating wastes is paramount to a lean journey or continuous improvement. Look around every aspect of life, and you will observe wastes. Knowing what wastes look like is the first step. Your best opportunity is to find ways to eliminate them from your work. Make something better, eliminate an unnecessary step, error-proof your processes, and make things better.

So is TIM WOOD my friend? For years, the answer was no. I had no time for him in engineering because he worked in production. Now that I see him clearly, I embrace him and use him to make me, my team, and my company stronger.

YES — TIM WOOD is my friend!


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Lean Principles Of Waste In Engineering

Engineering: Making Connections With A Group Of Introverts



Let’s face facts… Most engineers are introverts. We tend to be quiet, reserved, thoughtful, and recluse.

The old joke — how do you identify an extroverted engineer? She looks at your shoes instead of her own.

Now, not all engineers are introverts, and I understand this distribution. In my career, the extroverted engineer is a rarity on a team. I have known a few extroverted engineers, and they are fantastic! Many of my best engineers have been these introverts. How do I connect with them?

Energy Is The Key…


Introversion and extroversion concept

​A common misconception is introversion means shyness or a wallflower. Extroversion is the class clown or outspoken person on the team.

Terry Tipple, Tipple Consulting, taught me an invaluable lesson. Introversion and extroversion are based on energy. Introverts recharge batteries inside, and extroverts are fueled by the people around them every day. I have known very outspoken introverts, and I am one myself. I have also known quiet and reserved extroverts as well who simply like being with people.

How do you make connections with these introverts?

Play On Their Turf.


Engineers talk at work

​Because an introvert must exert energy in a social setting, they often need time to recharge before their next encounter. As a result, big meetings with many people may cause an introvert to be quiet and reserved. Sitting in an open office where chatter and conversations continue all day long is draining. Typical extroverted business roles in marketing, sales, and management can drain an engineer’s energy throughout the day.

When you know you are working with an introvert, come to their terms. Meet them individually to allow them to interact on a smaller scale. One-on-one conversations are simpler than these complex, multi-faceted meetings.

Give your introverts time between important discussions. Allow them to reflect, percolate ideas, and develop their thoughts. Attacking an introvert with a barrage of questions without that downtime is ineffective. Provide them the space to recharge a bit.

Defeating The Stigma Of Introversion…


Engineer writes down some notes

Because someone is quiet and reserved in a social setting does not define that person’s contribution. Often, the silent thinking person can offer great insight. They observe and refine. Their mind processes various pieces of information drawing conclusions from the various thoughts.

Being quiet and reflective can take similar energy as the boisterous person speaking for 30 minutes without a breath. Refraining from reacting to an action can allow for great insight while developing a response. Being the center of attention does not define success.

Step One: I Am Jim, And I Am An Introvert


Introvert concept

I was once described as a wallflower, and in many ways, I still am. I keep quiet in some situations, and I often reflect on the big picture before speaking my mind.

Would you be surprised I am a bass player in a successful cover band playing nearly 100 shows a year? Most weekend nights, I rock out to my band’s favorite tunes for dozens and hundreds of people. I put excessive amounts of energy into my performance. I confess: I have to work at this because it is not my default behavior.

I am deeply introverted. When tested, I bury the needle on these attributes. Yet, I can lead a team or perform for hundreds of people. I spend a lot of energy meeting the extroverts at their table. However, the next day I am exhausted. I need time alone to recharge and repair myself. After two weekend concerts with the band, I am a slug.

Extroverts — How Can You Relate?


Two engineers shake hands

Since your energy derives through interacting with others, meet us introverts face to face in a smaller setting. One-on-one helps. If you want our input in a social setting, do not call us out in front of a group. Ask us individually.

The big thing... do not judge our silence or reservations as noncompliance or competency. Give us the room to breathe, process, and assimilate. When you recognize our retreat, do not go in for the kill—allow us to back up and regroup. Attack will simply drive us deeper into our safe zone.

In all seriousness, simply give introverts a chance to process information. You may be pleasantly surprised by what we can offer. Our insight can lead to new ways of thinking. Giving us space allows our process to flow.

Can An Introvert Survive?


Professional women talk about an engineering project

The answer is yes. We are capable of thriving in an extrovert’s world. Sometimes, we need to act like our counterparts in situations that require us to be more open. Other times, we can use our introspection to see clearer views of the situation. Our alone time to recharge batteries is our superpower.

Introverted engineers unite! We collectively solve many of the world’s problems! We can be powerful forces in business to drive amazing results. We can overcome our “shyness” by providing unique insights. We can make a difference.

I recommend we introverts use our gifts and continue to change the world… even if only from the shadows!

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Engineering: Making Connections With A Group Of …

Is It Better To Be “Right” Or “Right Now”?



In business, time is money. Wasted time is a LOT of money. When you are completing an assignment, are engineers better off getting their work in on time or getting it right the first time?

Lessons From An Engineering Manager


Engineer talks about a project at work

In my day-to-day efforts, I need to balance my team’s execution versus their effectiveness. I have deadlines promised to the organization, and I strive to exceed these dates. I push my team to improve their performance by executing to their commitments.

Timing is great when everything is perfect. What happens when something is wrong?

Engineers are strangers in the business world. We think differently than others. We train to solve problems scientifically. We are often perfectionist striving to ensure everything is just so. Dates are a suggestion against developing the perfect solutions. We do not compromise.

Perfection is an ultimate goal. If the solution is six months late, what value does it bring for being perfect?

Tinker, Tinker, And Tinker Some More...


Engineer on laptop tries to figure out a problem

Many colleagues are tinkerers. They twist, turn, pull, and push to ensure everything is perfect. Precision is our king! They continue to work out minute details to the deepest degree.

Many in business find this behavior annoying. Analysis by paralysis is paralleled. Why can’t these engineers make a decision?

Engineers by nature want to be right and provide perfection. Often, this need leads to their own detriment.

So What Is Right?


Engineers work on computers

Business needs to move forward, and deadlines must be kept. Customers expect results on the day published. They want their stuff.

The same stakeholders also want their product to work. Mistakes are unacceptable, and functionality is required.

So how do you choose between right and right now?

Lesser Of The Evils...


An engineer's supplies

In many cases, I can negotiate with a customer for more time. I cannot bargain for function. The product must work well to fulfill the customer’s needs. Make it right the first time.

Sacrificing time for function will pay off dividends. The balance of being late can be offset by correcting mistakes later in production, by providing a product that does not meet specification, and by avoiding any sort of rework. Costs of a mistake late in the development cycle of a product can costs 10X, 100X, or even 1000X dollars to correct. The earlier these errors are discovered, alternatively how “right” it is from the beginning, the less expensive to correct.

This opinion does not provide carte blanche to engineers to take all the time in world. Remember, time is money. Being late to be right cannot always happen, and time is a finite resource. Sometimes, you must compromise a little perfection to maintain timelines.

How do you choose?

Giving Up Control Over Perfection


Engineers plan out a project

Each engineer within his or her career must learn the balance between time and perfection. Sometimes good enough is everything a project needs. Other situations require perfection.

Most people will explain this balance is only learned through experience. Over time, “you will figure it out.”

My best advice to any engineer is to be curious and ask questions. Ask your boss, what is most important to her agenda What is critical to the customer specification? How do I know what is important to get right versus having it complete right now?

Advice From A Sage...


Engineer shakes hands with a customer

Below, I have included a few “rules of thumb” to begin your journey.

If safety of another human being is a concern, lean towards perfection. Human life is far more important than a penalty for being late. If you feel something needs more effort to keep someone safe, take the extra time and the hit to protect your integrity.

When product functionality is paramount to customer success, take the extra time. Similar to safety, you must choose what is right. Making the product stronger with the additional effort will outweigh the penalties in most cases.

Trivial items are the places to relax on perfection. Is a bolt length 10mm or 12mm long? In many cases, the difference is miniscule. Knowing what is important versus trivial will help engineers maintain their schedules without sacrificing product integrity.

If you need to ask yourself, "Do I need to do more to make this 'right' and will anyone care?" then place the extra effort on this topic. If the decision seems trivial, ask your boss or a senior member of the team their opinion. If you cannot sleep at night knowing something in your work is not measuring up to your personal integrity, add the effort.

Early in your career, your choices are not clear. You will make mistakes. I recommend making them on the side of caution… making it right the first time. You can always ask for forgiveness on delivery; however, apologizing for an error requires much more effort.

I walk a line between both worlds as an engineering executive. I need things done NOW to satisfy my customer, and I need output to be accurate. I cannot always have both. When in doubt, I will defend my engineers who make it “right” versus the one who cut corners to make it on time. Right comes with much less risk to the customer… unless perfection becomes an obsession.

Strive to “make it right” every time, and over time, you will learn to exceed your committed dates.

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Is It Better To Be “Right” Or …

Revision Control – The Foundation Of Any Engineering Effort



What is revision control?

Simply put, revision control is the management of changes over time. If an object is released for use outside of development, a revision is initiated.

Whether you are writing software code, developing a CAD drawing, modifying a product or its tooling, and even editing a document, each time a copy is released from the governing task a revision is introduced. Controlling these various versions of a unit is critical to engineering success.

Why would something as simple as knowing a revision be so critical to engineering efforts?

  • Product Recall – consumers need to know if their product is good or bad. The revision will provide these details.
  • Consistency – by following a single revision, efforts are consistent across the board with the defined specifications.
  • Tracking Efforts – if everyone has a document with the same name and is working concurrently, how does the group know what is the most accurate and up-to-date version?
  • Maintaining Control – with a strong revision scheme, your processes will remain in control allowing improved efficiencies within the confines of the activity.

Lessons For A Young Intern


Engineer, architect

My first exposure to revision control was drafting for a major automotive OEM. At 19, I was creating and modifying drawings for major brands. I had power I did not fully understand—my lines and numbers on the page would influence thousands of products within a single platform. This new authority meant my mistakes would also perpetuate through the system.

I would handle dozens of drawings per week to either create a drawing or revise an existing product. I had the responsibility to capture engineering concepts and present them on this sheet of paper. My actions directly controlled how items were manufactured.

Each and every single change on this paper needed to be documented. If I moved one arrow, I needed to identify the change. If I added a line, deleted a circle, or even changed the color of an element, I was responsible to capture these changes within a revision to the document.

If I made a mistake, everyone knew it.

The 4 AM Call… From Chester


Man revises something while working

We had checkers on staff who would review every single drawing for detail. Comparing the old to new drawing or reviewing a brand new design, these checkers were responsible for accuracy. Chester was the toughest, and he abused his power.

I had recently made changes to an engine block drawing of approximately 20 pages. I had moved a bolt circle and some additional changes. Inadvertently, I made some modifications to the main area of the drawing when I made my final submission.

The phone rang on my desk (before cell phones and IM), and Chester was on the other line. He was not happy with me, and proceeded to scream, yell, curse, and berate me for 12 minutes… and it felt much longer. Each and every mistake I made was a “you dumb #$%*, how did you miss this?” question. I felt terrible.

Two hours later, the drawing appeared on my desk from a runner. I unrolled the paper, and it bled red ink. One marked up mistake after another. Some pages the redlines overtook the actual lines drawn in CAD.

One final message on page one… “You need to change the revision. You can’t collect these mistakes under the old rev. Fix it – NOW.”

I was scared I was going to be fired.

The Lesson


Revision concept

When I finished wiping up the blood (red lines), I submitted a new revision of my drawing. I worked tirelessly to ensure I got every markup Chester made. I printed and reprinted copies of the drawing to ensure each line was perfect. I sweated as I walked down the hall to his inbox. Dropping my drawing package in his office, I ran away fearing the worst.

Two days later, a bundle of drawings appeared on my desk with a note. The handwriting was unmistakable, it was Chester. “Much better kid. Two more quick things, and submit for approval. You learned your lesson.”

Whoa… I dodged a bullet.

Why Is This Important?


Engineer types on his laptop

While developing “work” within the team, revisions can become cumbersome, and they are often ignored during the creative process. As soon as you submit something to anyone outside of your group, you have released a version of your work product. You cannot control where it goes, who sees it, or who can change it. You lose the ability to protect the information.

By adding a revision each time something crosses that control line, you are taking a snapshot of the history of the product. You are recording the status of this object on this date and time. You make it a piece of history.

When someone returns with questions about this product or unit, you cannot control how they received the information or how it was manipulated. You can only control how it left your hands. Knowing what state an item is when you release it can eliminate many mistakes and arguments. It can also save you from litigation.

How To Manage Revision Control


Woman organizes papers and documents

Many people will think it is easy, and at its core, revision control is simple. The discipline and execution are hard… because of humans.

A simple rule to follow: if you change something after it leaves your control, revise it.

For example, I write you a letter confirming an agreement we made over a phone call. I send this letter to you for review before we sign it making the agreement official. This letter is in its original state when I release it.

During the review, you find I mistyped your company’s price by transposing two numbers. Nothing major, correct? I just fix it and send a new letter. We agree upon it, and we sign the letter. Two years pass, and my company wishes to invoice you per the agreement. You have two letters in your possession—the original and the revised. Which price is right? What did we agree upon? Neither of us can find the signature copy. Which value is correct?

Had a revision been included in the letter moving the original copy which we will call “A” to the revision copy “B,” the difference would be immediately resolved. “B” supersedes “A,” and I have a record of the change.

This example is overly simple to prove a point. Do you agree this revision control issue is exponentially worse in a multi-piece assembly similar to your car, an airplane, or even your cell phone? Add in layers of software and variations due to assembly, and the identification of your product becomes more challenging. Having robust revision control will save you significant effort in the end.


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Revision Control – The Foundation Of Any …

4 Reasons To Work For LiquidPiston



LiquidPiston is an engineering service provider that develops compact together with efficient engines for automobiles and power generation. Their own rotary engines are typically the first disruption to engine motor technology in over some sort of century, and they will be always on the search for talented engineers for you to join their team.

Do you want developing efficient thermodynamic burning engines? Here's why an individual should consider working to get LiquidPiston.

Information About LiquidPiston


LiquidPiston engine technology

LiquidPiston develops advanced rotary internal combustion engines in line with the company’s patented thermodynamic period and engine architecture in their state-of-the-art laboratory services in Bloomfield, CT. Their particular combustion engines are lightweight, powerful, quiet, efficient, low-vibration, and multi-fuel capable, and they are scalable from 1HP to help 1000 HP.

These engines are certainly not Wankel engines; they're much better. LiquidPiston boasts that their own X Engine has "10x more power" and is definitely "30% more efficient, inches improving on efficiency, excess weight, size, vibration, and noises.

LiquidPiston can be currently focusing on army and aerospace markets yet plans to enter commercial and commercial, marine, UAV, urban mobility, and auto markets in the close to future.

The engineering company appeared to be featured upon How It’s Produced , a documented series from your Science Route.

4 Factors To Work For LiquidPiston


Employees at LiquidPiston

1. Use an open-minded team along with varied engineering backgrounds

LiquidPiston's group of engineers are trailblazers and mavericks, people who challenge this status quo and therefore are often the first to bring brand new tips to market.

2. Observe your own ideas applied (in 1-2 weeks vs. 1-2 years)

Innovation is rewarded from LiquidPiston. Employees are motivated to push the limitations in the world regarding combustion.

3. Operate with minimum red tape

At LiquidPiston, you have the independence to explore your enthusiasm, which can lead in order to incredible opportunities.

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You'll participate in your whole engine/product development procedure from scratch and below one roof.

Benefits & Perks In LiquidPiston


LiquidPiston engine in action
  • Health and dental strategy
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Career Opportunities At LiquidPiston


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4 Reasons To Work For LiquidPiston