Category: Product Design

Todays client generally wants a product that is economical to manufacture, elegant, and robust. Robust products have an advantage in the market place. This is especially true in this age of the easy accessibility to user reviews over the Internet.

According to the Wikipedia,

Robustness is the quality of being able to withstand stresses, pressures, or changes in procedure or circumstance. A system, organism or design may be said to be “robust” if it is capable of coping well with variations (sometimes unpredictable variations) in its operating environment with minimal damage, alteration or loss of functionality.

Why is robustness important? Robust products perform as expected in a wide variety of situations, environments and contexts. Robust products often outperform expectations and delight users. Robust products have significantly reduced warranty returns. These products leave a positive impression on the user. Customers often respond by becoming local, or internet, evangelists for the products. These customers may also become life long users and purchasers of the product, or service.

Developing criteria to gauge the robustness of a product can difficult. Some industries and user contexts (such as military) already have specifications in place to gauge the robustness of a product. Unfortunately, many industries do not think in terms of robust products. Robustness can be a broad and vague requirement, especially if the approach to defining qualitative (and subjective) terms is not organized and methodical.

A good way to understand robustness, is to look at areas that are impacted by the robustness of a product. One area that robustness impacts is manufacturing. A robust product tends to be easier to manufacture because it is less sensitive to tolerances and other small variations in the process. When a product is less sensitive to changes in the manufacturing process, it is usually less expensive to manufacture. Robustness at the manufacturing level is often the result of well planned and executed design that avoided ?mission creep?.

Robustness at the user level is manifested in many ways. One example is having the product perform as expected on a continuing basis. An example of a robust design is the ignition switch in your car and the key to turn the switch. This switch is often used twice a day for ten or more years. The key that you started your car with today is probably in your pocket, or purse, as you are reading this article. That key is constantly (while carried in a pocket or purse) in contact with other metal objects such as change and other keys. Many times, at the end of the day, keys are tossed into a bowl or other container for overnight storage. Car keys see constant wear and abuse from the user and the environment. However, when you walk out to your car you, expect the key to turn the ignition and the car to start. The devices are used in a wide variety of environments from cold weather in the winter to hot weather in the summer. The user may be wearing thick winter gloves. Keys also must be adaptable for use in a wide variety of environments from a mans trouser pocket to a womans purse. They must be small enough to fit in a purse or pocket. The car key and ignition switch are examples of two very robust devices that function very reliably for an extended period in wide variety or circumstances and environments.

Robustness must be designed into the product from the beginning. One way to develop robust products is to determine (in the beginning of the project) exactly what product it is that you really wanted to design. Products must be well defined and targeted. Mission creep (the addition of unnecessary or previously unanticipated features) is the enemy of robust products. Mission creep is where the product design mission is expanded from the initial, targeted product. Mission creep diverts resources and time away from the appropriate product in an effort to extend the product into areas, or features, that arent critical for the success of the product. This lack of focus can result in extra product features at a cost to the robustness of the product.

Robustness also comes from a commitment to integrity in all stages of the design and manufacturing process. Customers expect robust products. Companies delivering robust products exceed the expectations of the customer. They are also creating an environment that encourages repeat purchases from satisfied clients and that is good for the bottom line.

Montie Roland is President of the Carolinas Chapter of the Product Development Management Association. Roland is also President of Montie Design, a product development and prototyping firm in Morrisville, NC and the RTP Product Development Guild. You can reach Montie by email at: montie@montie.com

 

Design, by its very nature, is an iterative process. The product design process begins with creating preconceptions. Those preconceptions are used to create a prototype. The prototype is then tested and the test results are evaluated. The evaluations are used to form new preconceptions and the process begins again. These iterative cycles can focus on the entire design, or they can focus on a small area (or technology) of the product. This process relies on prototyping and testing. Prototypes come in many forms. The word ?prototype? is commonly refers to a working model of a product, or product concept. A written, or verbal, description of the product could also be a prototype. A sketch could also serve as prototype. The exact nature of the prototype isnt as important as the effect of the prototype, which is to validate the success, or failure, of the product. As the design progress, the cycles of iteration become more focused, as the developers refine the product.

Different industries have differing levels of toleration number of iterations in a design sequence. Machine design is a good example of an industry with a low tolerance for iteration in the design process. Engineers that design machinery attempt to practice design in a very linear fashion. The goal in the machine design industry is to reach a finished, and proven, design in the least amount of time with the least number of changes or redesign cycles. This approach attempts to follow the straightest possible path to a completed design. This ?straight arrow? approach leads us to classify this industrys design methodology as a linear one. Even with this approach, iterations are necessary. Design iterations inevitably occur during the process of design a new piece of equipment. The can be caused by a machine, or system within a machine, that doesnt perform as expected. When this happens, that part, or sub-system, is redesigned and redeployed. Because of these issues the machine design industry does not have a completely linear process.

The linear nature of machine design is driven by two factors. The first factor is the prevalence of a function requirement and the minimization of aesthetic requirements. In my opinion, the biggest cause of the use of a linear design process in the machine design industry is the percentage of engineering and design costs as compared to the total cost of producing and marketing the machinery. Many machines are custom, or semi-custom, to the specific application (often manufacturing). This results in a small number of units to amortize the engineering costs against. This is a situation where the cost of design and engineering is a significant percentage of the total cost to produce the each machine. As a result, savings in the cost of design have a significant impact on the profitability of that design. This is the exact opposite of consumer products that have a low cost of design, relative to the total cost of producing the product.

Consumer products are examples of products with a very iterative design process. These products are typically produced in high volumes. This allows the cost of design and engineering to be amortized over a large volume of product sales. In higher volume products, there is more incentive to spend more time on the industrial design and front-end design (fuzzy front end) stages of the design process.

Any product, or service, will be judged by the market place based on the experience that the product provides. Machinery is evaluated on institutional-experience criteria including performance, ease-of-use, speed of installation, return on investment (ROI) and uptime. Consumer products are evaluated on end-user experience criteria that include ease-of-use, aesthetics, coolness, usefulness, perception that the product creates and the experience that the user has when interacting with the product. The latter criteria can be very subjective and difficult to capture in any sort of written document.

Products with great user experiences often succeed in the marketplace, where products with poor user experiences fail to generate sales. This does not mean that user experience is the only indicator of potential success. A product may have a compelling value to the customer that overcomes a poor user experience. Typically these products are the first in their class and provide some functionality that is new to the industry. This is a case where the value to the customer is high and the customer will accept a poor user experience in exchange for that functionality. As a segment of an industry matures, the user experience becomes a more important indicator of how well the product will sell in the marketplace.

The current game console war is a good example of this contrast between functionality and usability. The PlayStation 3? is a game console that has an average user experience, but provides state-of-the-art computer graphics. The Wii? is a game console that provides average computer graphics, but has a wonderful user experience. The Wii? has outsold the PlayStation 3? by about twenty percent.

Product iteration allows the design team to explore a variety of concepts. The evaluation of these concepts helps to decide which concepts to integrate into the product and which concepts to drop from the product. Many times the issue isnt whether a concept is good, or bad, but rather ?is it appropriate This is especially true when the design team is evaluating, and improving, the user experience of the proposed product.

Product developers, designers and engineers use the available resources (which are always finite) to work towards achieving the best product possible. The nature of the product and the expectations of the industry and customer ultimately drive the exact nature of the design process. Design is iterative. Product designers rely on experience and a refined process of iterating through the design cycles to create the next product. Often a designer achieves success not by any one single action, but by the consistent application of an educated, and refined, design process.

Montie Roland is President of the Carolinas Chapter of the Product Development Management Association. Roland is also President of Montie Design, a product development and prototyping firm in Morrisville, NC and the RTP Product Development Guild. You can reach Montie by email at: montie@montie.com

The product development world, just like other industries, has its own language. One example of this ?product speak? is the term product champion. Many products (and most of the very successful products) are driven by the vision of one person, or a small group of people. We call these people ?product champions?.
Product champions drive new products to market through experience, use of available resources, drive, determination and vision. They have a vision for a product. They work with others around them to push that product out to the market. This new product can be an extension of existing products in a existing company. The vision may be bolder and push an existing company in a direction.

A good example of a new direction for an existing company is the Apple iPod. Apple is a computer company that struck out into the personal entertainment industry. The biggest leap is when a product champion has to build a new company around a new-to-world product. When that vision incorporates technology and design practices from two or more industries (what we call cross-pollination) the opportunity exists for a truly disruptive product. Disruptive products change the marketplace and can propel a manufacturer to a position of market leader.

Product developers categorize new products into four areas. The first category of product development deals with incremental advances. An example, is a company that makes 42-inch plasma televisions decides to create a 44-inch model. Generally, these products make incremental, or evolutionary, leaps forward in technology or design.

The next area is a class of products that are based on existing products, but make revolutionary leaps in the state of the technology or the design approach. These products can dramatically affect an entire industry and drive market share to new heights, or help a company establish a presence in a market space that they werent previously able to penetrate.

Me-too products are designed compete with existing products. These products may be new to company that manufactures them, but they are not new to the market. Me too products generally are designed as direct competitors. They are generally not very innovative in their design.

New-to-world products are exactly what the name implies. These products are often technologically innovative and higher risk. They do not exist in the current marketplace, or they use a technology or a design approach that is not currently available.

The Apple iPod was not a new-to-world product. An existing market space for MP3 players existed for several years before the iPod arrived on the scene. The designers of the iPod combined improvements in four key industries to make the iPod a massive success. Apple improved the state of the basic product by designing the click wheel interface. This interface was a significant improvement over the traditional interface provided by existing manufacturers such as Rio. These advancements were revolutionary in that industry.

Apple went farther by bundling the product with iTunes. iTunes was software product that leveraged Apples core competency with computers to deliver content over the internet. iTunes also made it simple and easy to update the iPods firmware. Previous MP3 players required more-than-average expertise to simply update the firmware. Apple changed the user expectations about how easy it should be to purchase and download music to the player. They also changed the industry by creating users that expected painless firmware updates through iTunes. While the iPod was not a new-to-world product, iTunes was a new-to-world product.

The product champions at Apple had the vision to create a well-integrated product that combined advancements from multiple industries including electronics, audio compression, internet technology, service, and software. The amazing part is that existing manufacturers in the MP3 player market space were concentrating on the player itself and the software to drive the player. At the time the internet was mainly be used a vehicle to move data, but not as an integrated part of the user experience. The product champions at Apple saw an opportunity to cross-pollinate between multiple industries and create a market dominating product.

The RTP Product Development Guild has core philosophy that the most disruptive products come from the cross-pollination of technology and design knowledge from two or more different industries.

Product champions do not necessarily have to have experience from within multiple industries. The key is to have a vision that integrates technologies and practices from multiple industries into a single product. Then you have an opportunity to create the next highly disruptive and highly successful product.

Starting a Product Development Guild has been a journey that has lasted about two and a half years. The first two years were mainly discussions. The last five months have mainly involved laying the groundwork for the guild. We have now moved into a mode where we are starting to recruit members and look at project submissions.

Tom Vass first mentioned the idea to me two years ago at Carolinas PDMA event. At the time, I really didnt think much of the idea. It took several conversations for me to realize that the problem wasnt with the concept, but rather in the articulation and execution of the concept. So we spent about two years, off and on, discussing the concept and refining how we articulated a complex sounding concept.

One of the critical questions in developing in the Guild is ?why does the concept seem so complex The concept, in the simplest form I can come up with, goes something like this:

Consultants, and other product design professionals, band together in a contractual organization. This aspect of the organization most closely resembles a volunteer fire department. Guild members pay quarterly dues and an initiation fee to join. Guild members are proudly displayed in the Guild directory which is available online and in a print format next year.

Product champions submit project proposals to the guild in a structured format. The Guild evaluates each submission and picks the best submissions. The Guild looks for product concepts that are going to help launch product-driven companies. Products that combine technology from two different industries are given priority.

Once a product concept is selected, the product champion becomes the nucleus of a seven member team. Project champions can be inventors, entrepreneurs, serial entrepreneurs, a designee from a start-up company, or a designee from an existing corporation that has a product concept that they would like to spin-off into a new company. Six of the seven team members are product development professionals. These members could come from disciplines such as industrial design, engineering, software, electronics, business management, marketing or sales.

Projects run for six months. The goal of the project is to complete the fuzzy front end design of the product. At the start of the project, the Guild receives options for the clients stock. These options can only be exercised upon a trigger event such as a sale or initial public offering (IPO). At the end of the project the Guild transfers a portion of those options to team members.

Projects are structured so Guild members spend two to four hours per week on the project. The product champions (client representative) spend fifteen to twenty hours per week on the project.

The team makes a presentation at the end of the project to selected angel investors and venture capitalists. This last step of the project is designed to help the client get funding for the next step in designing and then commercializing their product.

The goal is to complete twenty six month projects per year (ten every six months). This would add twenty new, high-growth companies to the RTP area each year and significantly impact the local economy. This means that the efforts of approximately one hundred and twenty Guild members can help drive the future economy in the regional area for the next ten to twenty years..

I am still struggling with how to present this in a thirty second elevator pitch. This is not an overly complex process when you consider the amount of work to be done. Sometimes I wonder if the previous presentation is trying to explain too much. Maybe the elevator pitch should go something like:

The RTP Product Development Guild is a confederation of product design, and business, who work together to help local entrepreneurs and businesses commercialize their products. The Guild seeks to improve the regional economy in North Carolina by helping create now product driven companies.

Salesmen reading this article are probably wondering why not just use the shorter version first. This is the difference between salesmen and product designers. Engineers and industrial designers often focus on how wonderful, and cool, the details are. A good salesman wants to convey just enough information to close the deal. They know that giving too much information is a possible way to talking your client out of doing business with you. The role of President of the Guild requires me to live in both worlds. This can be challenging at times. Product developers must always keep in mind that successful products find a balance between design and execution.

The chicken, or the egg, syndrome is alive and well at the RTP Product Development Guild. On one hand, we need a strong portfolio of consultants to attract product concept submissions. One the other hand we need strong product concepts to attract consultants. This means that there is going to be slow progress between now and the kick-off of the first project. We have spent the last month lining up product submissions and potential Guild members. The first inquiries about memberships are mostly coming from sales and marketing professionals. Another high interest area is the service providers. We have a class of Guild memberships that are designed to allow service providers to participate in the Guild without having to participate in a project team.

Another concurrent action item is to promote the Guild within the economic development community. North Carolinas economic development community is heavily focused, and politically invested, in the mode of using massive tax incentives to bring existing companies to North Carolina. There are other efforts that focus on using the universities and community colleges as concentrators of innovation. The Guild believes that there is enough talent, dedication and ambition in the local community to create new product-driven companies. This ?believe in the people? approach is counter-culture. The Guild isnt relying on tax incentives or government grants to drive new products to market. We are relying on our members to work together and help lift new companies from the stage of ?I have an idea? to the stage of ?we just rented office space?. Dreams are best pursued by the dreamer. It is hard to pursue someone elses dream. Product champions rev up your dreams, because you now have a home.

Montie Roland is President of the Carolinas Chapter of the Product Development Management Association. Roland is also President of Montie Design, a product development and prototyping firm in Morrisville, NC and the RTP Product Development Guild. You can reach Montie by email at: montie@montie.com

The term “fuzzy front” end is used by product design professionals to denote the product definition stage of the project. This important stage in product development is often neglected. In this podcast well talk about what the “fuzzy front end” is and why it is important.

You can listen to the podcast by clicking here.

Montie Roland is President of the Carolinas Chapter of the Product Development Management Association. Roland is also President of Montie Design, a product development and prototyping firm in Morrisville, NC and the RTP Product Development Guild.

by Montie Roland, President – Montie Design

Product design in the RTP area is nothing new. Entities that vary in size from the smallest startup to the largest multi-national companies are engaged in a daily business of product development. These companies dont practice the art and science of product development in a vacuum. They rely on an infrastructure of local vendors that provide a variety of services and products.

Since moving into our new office space where we added an embedded machine shop, and becoming a part of the RTP Product Development Guild, the Montie Design business model has changed dramatically. The biggest change is how much tighter we have integrated with the product design community around us. Our firm has relied on the services of other vendors for years, so in itself this is nothing new.

The new offices opened in June of 2007. Approximately one month later, we were joined in the office by Brandon Lisk and 101Machine. The office space included a shop and office area big enough for both companies. The rationale for having them in the same space allows both companies to offer more vertically integrated services. Consulting firms operate with remote (across town) vendors every day, but being in the same building allows a greater level of cooperation and coordination, thus relieving pressure from clients to have an in-house machine shop.

What I didnt expect was how it would change the Montie Design business model. Once 101Machine was up and running, clients began expecting that Montie Design would do several things. The first was to handle the prototype builds directly. Previously we would design the product and create the documentation. Then we would recommend a machine shop and get a quote. The client would then take that quote and issue a purchase order directly to the machine shop (or other vendor). Now clients expect us to manage the prototype build and handle the billing so they just have to create one purchase order. This arrangement makes it more convenient for the client and gives us a higher level of control over the process. However, it also added a new layer of administration that we have accommodated for. As a result, we have begun issuing purchase orders to vendors and tracking them. This was a big change for a small, but growing, company. It was a welcome change because it has allowed us to offer a broader range of services that arent directly tied to the number of billable hours. It also requires tighter financial controls because of the larger, and more complex, cash flow requirements.

Not all prototype parts and pieces can be economically produced by a single machine shop. An example was a group of physically large parts that were beyond the normal capabilities of 101Machine. Barnes Machine, in Apex, was able to very cost effectively produce these parts in a very tight time frame. This was a case where we were able to produce a set of prototype parts in an off-site location as a service to our client. JMC Machine is another example of an off-site vendor (also located in Apex). We have worked with Glenn Berry and Howard Nystrom for over a decade to produce parts for customers.

We also work closely with ADR Hydrocut to create complex, flat parts. ADR Hydrocut has two water jet cutting machines. The water jet process uses an extremely thin column (fifteen times the thickness of a human hair) of water mixed with an abrasive to cut complex shapes out of sheets of just about any material. Their business model relies on quick turnarounds of parts. This means that you can usually order a part and receive it within five to ten working days. One of the advantages of our current office location is the close proximity to ADR Hydrocut. This proximity and close working relationship with the owners, Al Ely and Ron Harris, allows us to work hand-in-hand with them, which is critical on projects with tight time restrictions.

The value of the relationship with JMC Machine and ADR Hydrocut has gone far beyond any one project, or one customer for that matter. The personal relationships with the owners of these companies have lasted for over a decade. These are people that I call friends. As it is always critical to not confuse friendship with what is best for the firm, or the customer, I find it wonderful to be able to work with a group of friends whom you can trust.

So how does all of this tie into the subject of a design community? Much of our success as a design firm is related to the availability and performance of the vendors that support us. Without the vendors behind us, we could not serve our customers at the level to which they have become accustomed. Adding a level of vertical integration has allowed us to expand our services, but at the same time has highlighted our need for quality relationships with reliable vendors. Relationships such as these help form the backbone of the product design infrastructure that is such a vital part of product design successes in the Research Triangle Park area.

Hey All,

I just wanted to let you know that our Grand Opening and Expo is coming soon. Please take an afternoon out to enjoy good food, tour our new facility, and meet local product design/prototyping vendors. The event is free.

See you there.

Montie

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Event: Grand Opening / Pig Pickin / Vendor Day for:

Montie Design

101 Machine

Better Business Advice

RTP Product Design Guild

Date: Saturday, 4 Aug 07

Time: 3:00 until 6:30

Location: 400 Dominion Dr., Suite 101, Morrisville, NC 27560

Description: Join us in celebrating the co-location of:

RTP Product Design Guild
Montie Design
101Machine
Good Business Advice

Stroll through the various outdoor vendor booths including:

– Montie Design – product design
– 101Machine – prototype machining
– Good Business Advice – business ansurance and financial mgmt
– RTP Product Design Guild – community-based design
– Pioneer Strategies – public relations
– Fineline Prototyping – rapid prototyping service bureau
– ADR Hydrocut – waterjet cutting house
– Applied Technologies – product design

Bring your family and join us for an afternoon of fun! Please dont hesitate to send any questions to: montie@montie.com

Register (free) at: http://productdesignguild.eventbrite.com/

Morning Fellow Product Designers,

I thought this event might interest many of you.

Montie

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Event: “New Product Development in the Entrepreneurial Enterprise”

Date: 14 Jun 07

Time: 6-8:30pm

• Networking & Registration 6 – 6:45 pm
• Presentation and Q&A 6:45 8:00 pm
• Pizza and drinks will be served

Location: MCNC auditorium in RTP, NC

Speaker: Bob Luddy, President, CaptiveAire and founder, Franklin Park Industrial Center

Co-Hosted by: CED

New Product Development in the Entrepreneurial Enterprise

Unless your business changes, your business will die. Changing means developing new products. But what new products? Why one product over another? Where do you begin?

Learn what inspired Robert Luddy, lifelong entrepreneur and president of Raleigh-based CaptiveAire Systems – the nations well-respected manufacturer of commercial kitchen ventilation equipment. Luddy founded CaptiveAire in 1976 on $1,300 capital. Today, CaptiveAire employs 650 people in four plants and 57 offices in the U.S. and Canada. It is continually voted ?Best In Class? by industry dealers and consultants, according to Foodservice Equipment & Supplies magazine. INC. magazine has repeatedly named CaptiveAire one of the 500 fastest growing private companies in the nation. In North Carolina, CaptiveAire is among the 100 largest private companies (Business North Carolina magazine), and it is the 10^th fastest growing private company in the Raleigh Triangle (Triangle Business Journal).

Learn and discuss with Bob:

• How you can revolutionize your industry.

Keys to competitive success.

How to navigate the challenge of offering increasingly higher-quality products at the lowest cost.

Bob will cover these and many other topics, including responding quickly to market demand. Please join us to exchange points of view, build relationships with your peers and as gain insights from our speaker:

Robert Luddy is a lifelong entrepreneur. At the age of 20, while attending LaSalle University in Philadelphia, Bob opened a fiberglass manufacturing business and worked at night. In 1967, Bob sold his company and was drafted into the military. In 1976, Bob settled in Raleigh, and with $1,300 capital, he opened Atlantic Fire Systems in a one-room facility. Recognizing the demand for high-quality kitchen ventilation equipment, Bob purchased a sheet metal shop in 1981 and transformed it into CaptiveAire Systems, Inc. CaptiveAire is now the nations largest manufacturer of commercial kitchen ventilation systems, with sales reaching $180 million in 2006. In addition to CaptiveAire, Bob Luddy drives other economic development in the area. Bob founded and developed the Franklin Park Industrial Center, which has drawn over 15 entrepreneurial businesses and hundreds of jobs to Franklin and Wake counties.

Questions? Send an e-mail to montie@montie.com