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What do you do if your design is plagued with problems?

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Discovering that your engineering design is riddled with issues can be disheartening, but it's a critical juncture that tests your problem-solving skills and resilience. It's important to approach this situation methodically, assessing the problems without bias and considering the implications of each issue on the overall design. This process often involves going back to the drawing board, but it's a necessary step to ensure the functionality and safety of your design. Remember, encountering problems is an integral part of the engineering design process, and addressing them effectively is what ultimately defines a successful engineer.

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1 Identify Issues

When you're faced with a problematic design, the first step is to conduct a thorough analysis to identify all the issues. You need to break down the design into its components and examine each part for flaws or inefficiencies. This might involve simulations, physical testing, or simply reviewing your calculations and design assumptions. It's crucial to document every problem you find meticulously. This will help you prioritize the issues and ensure that you don't overlook anything as you move forward with troubleshooting and refining your design.

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Prabhat Chaudhary

Client Acquisition Specialist @ 5Core Digital Marketing | Digital Marketing Strategy | Mechanical Engineer
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When dealing with a problematic design, start by identifying root causes through thorough examination and stakeholder feedback. Brainstorm solutions collaboratively, considering both simple adjustments and potential design overhauls. Communicate openly throughout the process to foster innovation. Implement changes and rigorously test them to ensure effectiveness. Embrace challenges as part of the engineering journey, iterating until achieving resilient solutions.

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Zulfiqar Hussain

Head Of Department - Process Engineering
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Multiple design issues are a symptom of inappropriate concept selection. Go back to concept, you may have chosen the wrong option. Start off with understanding the design basis and make sure your inputs, outputs, boundaries and functionality align with your customer. If parameters have changed from your initial basis, ensure that any change impacts have been fully captured and if not reassess the applicability of your design. If all is aligned then look at yout team as you have serious quality issues. Finally be honest and open with all stakeholders about errors and mistakes and ensure you have an open culture in your team where people can raise issues, foster innovation and are rewarded for openness.

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Munonyedi (Nivlek) Egbo, PhD, PE, PMP

Thin Film Install-Qualify (IQ) Engineer @ Intel Corporation || PSM 1 & PSPO 1 Certified || Researcher || Former Professor of Mechanical Engineering
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It is also important to note that some times the problem isn't with the individual components/parts of the system/process but their compatibility.

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2 Root Causes

Once you have identified the issues with your design, the next step is to investigate and understand the root causes. This involves a deep dive into why each problem is occurring, which may require revisiting your initial assumptions or the constraints you're working within. Sometimes, it's a matter of materials not behaving as expected, or perhaps there are unforeseen interactions between different components. Understanding the underlying reasons for the problems will guide you in making effective and targeted adjustments to your design.

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Munonyedi (Nivlek) Egbo, PhD, PE, PMP

Thin Film Install-Qualify (IQ) Engineer @ Intel Corporation || PSM 1 & PSPO 1 Certified || Researcher || Former Professor of Mechanical Engineering
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This is where the well-known robust problem solving techniques such as the root cause analysis (RCA) and 5 why come in handy. Of course the selected technique will depend on the type of problem you are trying to identify and solve.

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3 Explore Solutions

After pinpointing the root causes of the problems in your design, you must explore potential solutions. This phase is about creativity and innovation as much as it is about technical knowledge. Consider alternative materials, different structural approaches, or even a complete redesign if necessary. Evaluate each potential solution for feasibility, cost, and impact on the overall design. Remember, the goal is not just to fix the issue but to enhance the design's performance and reliability.

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4 Test Iterations

Testing is a non-negotiable aspect of engineering design, especially when addressing problems. After developing potential solutions, you need to create prototypes or models to test these iterations under controlled conditions. This process might reveal additional issues or confirm that you've successfully resolved the initial problems. Each test provides valuable feedback that informs further refinements. It's often a cycle of testing, analyzing results, and tweaking the design until you achieve the desired outcome.

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5 Implement Changes

Once you have a solution that successfully addresses the problems in your design, it's time to implement the changes. This step requires careful planning to ensure that modifications are integrated seamlessly into the existing design. It might involve reworking drawings, updating specifications, and communicating changes to all stakeholders involved in the project. Implementation should be done methodically to avoid introducing new issues and to maintain the integrity of the design.

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6 Monitor Results

Finally, after implementing changes to your design, it's essential to monitor the results over time. This involves continued testing and observation to ensure that the problems have been resolved and that no new issues arise. Monitoring also includes gathering feedback from end-users or clients to assess the practicality and effectiveness of your design in real-world conditions. Continuous monitoring allows you to make any necessary adjustments and ensures that your design remains functional and reliable long-term.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What do you do if your design is plagued with problems?

1

2

3

4

5

6

7

1 Identify Issues

2 Root Causes

3 Explore Solutions

4 Test Iterations

5 Implement Changes

6 Monitor Results

7 Here’s what else to consider

Engineering Design

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What do you do if your design is plagued with problems?

1

2

3

4

5

6

7

1 Identify Issues

2 Root Causes

3 Explore Solutions

4 Test Iterations

5 Implement Changes

6 Monitor Results

7 Here’s what else to consider

Engineering Design

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