How can you overcome common mechanical design project challenges and risks?

One thing I have found helpful is to really put some time into this. You will get your constraints from users or clients as your overarching requirements. But you need to really think about what finer design requirements you can add to these that define specific design criteria that can easily be tested that ensure the requirements are met. But these constraints have to be realistic. Many times they can be defined on non-realistic criteria that end up costing you more time and energy to try to achieve. If you can't then you spend time on justifying changing them. Either way it slows things down and makes it more difficult. In addition, having a rough plan on how you test and verify them upfront will save time later in the project.

In my experience here are some steps to overcome challenges and risks in Mechanical design projects. - Clearly define project scope and objective - Check for old similar project documents to learn from past experience - Conduct brain storming sessions to start effectively and with fresh and new ideas - Maintain healthy communication throughout life cycle of project - Maintain project document and try to keep an eye on timeline and budget - Look out from different perspectives to recognize challenges by performing reviews at intermediate levels - Involve colleagues from all relevant departments to make sure we have inputs from every angle - Document lessons learnt during the project to refer for future similar projects

To overcome common mechanical design project challenges and risks: -Clearly define project objectives. -Assess and manage risks. - Foster cross-functional collaboration. -Prototype, test, and iterate. -Manage budget and resources. -Conduct design reviews and document changes. -Carefully select materials. -Manage suppliers and vendors. -Ensure regulatory compliance. -Implement quality control and assurance. -Maintain open communication. -Have contingency plans. -Utilize project management software. -Learn from each project for continuous improvement.

I am agreed to the first step about Scope and Objectives. As a design engineer one should be knowing first the output requirement from which we can look for the input requirements which will be followed by the process. So defining output, input and process is most important initially. Once we got these.. we will be able to forecast other parameters e.g. Han and technical resources, working hours, budget and so on.

Being prepared for the challenges in a Design project as well as overcoming them is what makes the project more meaningful! According to me, these are some of the key steps required to overcome these challenges : 1. Create a Product Development strategy: Follow the Product Development / NPI cycle thoroghly. Define the goal and scope of the design project, identify key characteristics, roadmap, timelines and an overview of feasibility 2. Use tools for Product / Process Validation: Tools like FMEA, DVP&R and Control Plan with the cross-functional team helps to be prepared for challenges to come 3. Learn from past experiences: Use the lessons learnt to your advantage 4. Collaboration: Ensure the cross-functional team is involved throughout

Agreed. One thing that can't be understated is doing the research to see things that have been tried and not worked which can help you determine the more efficient path. This will also help you determine affective and realistic design constraints. However, if you find some examples of things that work, don't put all of your eggs in one basket with that example. There are usually other concepts that will work even better. Further this research will help you determine what risks others have faced so that you can address them earlier instead of later which is always better.

One thing that i've seen is everytime the projects end many of the project team moved to other project or Company and they bring the good lesson learned together with them. So when we start a new project with a new team most of the time we will repeat the same mistakes or the same trouble. It would be good practice to collect and provide a project lesson learned prior the project ends, and when want to start a new one we can start to visit the previous project lesson learned atbthe beginning. It can help alot to shorten our research and analysis time everytime we want to start a new project.

Before starting any design thorough research is always plays an important part. Using past experience or following the design of similar projects will help mitigate the problems that might come or even can be avoided in the first place.

1. One thing the industry sector has to give credit to the academia is the academia "research" sector. 2. Always look for quality journal/conference papers that helps you to gain an in depth understanding of the subject matter. For example, a design engineer has to frequently encounter FEA problems and not just the modeling issues. Someone, somewhere might have published similar problem in their recent research papers. If the research paper is good, the reference section of that paper will take you on an adventure ride. Sometimes you would hit gold mines in that section. Sometimes there is no need to recreate the wheel. 3. Always summarize your research papers in a note, so that it is easy for you to get back to it. 4. Do, check, Repeat!

In my opinion, there is a significant underutilization of recorded lesson learned, particularly during the design phase. We are excellent at documenting our lesson learned, but we frequently fail to use those lesson learnt, which is why we consistently make or encounter the same mistake.

I agree but dont forget to collect the valuable inputs from your site team, sometimes they can provide an information related with the good design practice, operability issue anf maintanability issue that you might not captured in the books since every plant/facilities will have their specific conditions and need you to adapt on design.

Keeping the lessons learned to avoid repeating mistakes is really important. There are usually underlying contributing factors with the present problem. And this knowledge can't stop at a few seniors that have been there for 10+ years, it has to be archived and communicated in a way where it is possible to find. If all the old knowledge is in an old paper report which is thrown away , or scanned without meta information the risk for repeating mistakes is higher. Persons with experience are really valuable.

A proactive approach in the design with the various tools available, viz., FMEA (Failure Mode and Effect Analysis) - both design and process, would avoid in service failures and increases product safety. One another major consideration to be made in design is the Product Lifecycle Cost and not just the product cost.

It is always important to establish and communicate to others on the project what standards you are working to and to learn what standards they are working to. It is important that the standards being used on a project align and the required calculations etc give this information. communication of these facts is essential.

Consider the user. Who will be using your design? What are their needs and expectations? How will they interact with your design? Treat them has todlers who is trying to play chess, they will be wrong but they might lead you down a path that you didnt consider Also Test your design. Once you have designed your solution, it is important to test it thoroughly to ensure that it meets the specifications, performance, and user needs.

This step is very critical. I find that I can come up with great ideas on my own, but more often than not, the ideas created when collaborating are much better (depending on the complexity). One thing that may not be addressed in this article as is, is finding the right resources. Not just in equipment, tools, and space. But building the correct team for the project is crucial. Being able to determine what experience and what expertise you need is so important. not just mechanical vs electrical or software, but people with specific specialties within those roles. Then defining exactly what each person is responsible for so everyone has something to own. No one is an expert at everything, so get the right team will leave no holes.

Masterful communicators create masterfully crafted products. There are several communication pathways to master, and if you can discipline yourself in each of them, you'll be a desirable business partner, team member or consultant, ready to tackle any challenges that come your way. - be punctual and professional to the best of your ability, and look for ways to improve regularly. - maintain a high level of technical information of anything you build, so that when customers or executives come knocking, you've got everything organized and accessible, always. - don't delay raising concerns or issues until the 11th hour. Be up front and responsible for what you're trying to achieve. - maintain a lazer focus of the product goals, always.

Clear communication is absolutely required, however in my decade in New Space I often found that asynchronous communication was the best route. Our team achieved this by giving the client access to the project management tool, delivering weekly updates on an agreed upon format, and recording videos that supported our design update presentations. Only after everyone was up to speed on those materials did we meet, since often meetings stretch and morph much longer than needed. Remember: Meetings are for checking in and agreeing on the work, not for doing the work. Keeping everyone on the same page at their own pace meant we were more efficient, and didn't have to spend all day on Zoom!

One think i found critical is to put a right person in the right place, develop the roles & responsibilities by Top-Down approach, get solid with your team. And eventhough this has been done we still need to bound with other discipline/section/department. It is a good practice also if you can have a session that bring the team to gather together and get to know to each other before you start a project, at least it will create a bound among the teams.

When it comes to mechanical design, communication plays a crucial role. Building a solid network of technology experts from different fields can significantly enhance the design process. We sometimes get too invested in our designs, leading us to overlook potential problems or simpler solutions. We should regularly check in and consult with our peers and experts to avoid this. This approach provides fresh perspectives and often leads to discovering straightforward and cost-effective solutions that may have been overlooked. It's important to remember that our initial idea may not always be the simplest or best, even if it seems brilliant. We can stay objective and efficient by keeping an open line of communication with trusted colleagues.

Overcoming common mechanical design project challenges and risks requires careful planning, effective communication, and a proactive approach to problem-solving. Here are some strategies to help you address these challenges and mitigate risks: Define Clear Project Objectives, Risk Assessment and Mitigation, Effective Communication, Cross-functional Teams, Prototyping and Testing, Design Reviews, Budget and Resource Management: Technology and Tools, Documentation and Version Control, Quality Assurance, Regulatory Compliance: Supply Chain Management, Contingency Planning: Project Tracking and Reporting, Lessons Learned: Continuous Improvement. Encourage a culture of continuous improvement within your team and organization.

Invest time into systems and detailed designs so if you get repeat work you are not having to add more hours as someone originally cut corners. Ensure documentation is always kept well organised to compare any future work. Apart from these keep a log of any issues that happened during the project and with any repeat work ensure to listen to those comments. Risks can be lessened by checks at each stage before issuing documents.

I agree, we need to define the test method, test parameter and acceptance criteria clearly. Ensure all these parameter well understand by all parties. And another important thing is a Record on every test that we have done, ensure its traceability and a Test Report that signed by all parties.

Sometimes it takes months to deliver even a working prototype. The team needs to clearly understand the process of the mechanism/machine/project to make a realistic validation process. Got to know what you expect to be the outcome.

Testing at the end is a good recipe for disaster. The more important component/functionality, the earlier its functionality must be confirmed in real life preferably outside the lab environment (unless intended use is in the lab)... how? Just start with the scientific method and what actually is the Minimum Viable Product to be tested. Testing plan should be created as soon as possible for critical components/features. Everything you design depending on the important component/functionality will be worth nothing if you need to change the plan and need to be redesigned either slightly or completely causing potential multiple iteration rounds for huge network of interdependent components/features within project scope.

I didn’t contribute to the previous five project statements because I believe those are standard PM guidelines that should always be followed. If you are trying to overcome common mechanical design project challenges and risks, the first thing you should do is keep a ‘lessons learned’ log of all your project challenges, for every project, while you’re going through them. Second, review those challenges prior to starting your next project so you can avoid making the same mistakes. You will find the “common” ones disappear and you are only left with the unique, application specific ones.

When I come across an issue during a project I start by determining the cause of the issue. it sounds simple, but only with experience can you really take unbiased look at your work and examine where it went wrong. You can't be afraid to admit you or a coworker made a mistake. Owning it up front will speed up finding a solution. From every difficulty you learn what not to do and gives you more things to think about upfront. With experience, I find I'm more efficient at determining what real risks there are so I can address them up front. I will always run my designs by others before finalizing to have a fresh set of eyes to see if I may have missed any risks. This further stresses having people you trust on your team for feedback.

Fail fast. As the "smart ones" we have a paralyzing fear of failure or of making mistakes...it's a bit unhealthy. Make decisions, and act upon them. If they're wrong, correct them, LEARN from them, and continue. It beats making assumptions and sitting in a meeting room discussing the project to death, while precious time ticks away.

Overcome common mechanical design project challenges? That's what engineering is! We are solution providers. I'd like to pivot the question and ask "how can we identify unique (emphasis on unique) challenges and risks before they become a real issue?" For some risk averse clients, we have prepared risk registers where we identify risks, their probability factor, cost impact and schedule impact. This is conducted at the beginning of a the project with a dedicated meeting. Throughout design, the threats are tracked and either mitigated or fully addressed through the design. For most projects, particularly small ones, this is unnecessary, but a great tool to implement for larger projects if needed!

A great way to mitigate challenges and risk is through a strong culture of lessons learned. Very few problems are truly unique. If you have a culture of reviewing lessons learned before starting any project you can avoid pitfalls that have occurred during previous projects. If you will continue a culture of lessons learned during your project you will only have to mitigate that specific challenge once.