How Custom Engineering is Transforming R&D Workflows

Key Concepts

• Custom Engineering
• Off-the-shelf Solutions Limitations
• Innovation in Machine Design and Automation
• R&D Project Management
• High-Impact Engineering Teams
• Design Process
• Automation Trends (Controls, Hardware, Integration)
• Entrepreneurial Operating System (EOS)
• GWC (Gets it, Wants it, Capacity)
• Non-Recurring Engineering (NRE) Costs
• Importance of Communication and Customer Alignment

Bravo Team's Focus and Expertise

• Bravo Team is an innovation partner specializing in custom machine design, automation, and advanced R&D.
• They help other companies, mostly engineers, with open-ended design problems.
• The team comprises over 30 engineers (mechanical, computer, and electrical) and five machinists/fabricators/welders.
• They offer design and innovation services for hire, focusing on hardware-centric solutions related to products or manufacturing processes.
• Example: The Bravo Walk, a dog collar that trains dogs not to pull on a leash, is an example of their own product invention.

The Limitations of Off-the-Shelf Solutions and the Need for Custom Engineering

• Off-the-shelf solutions often fail to address complex engineering problems, especially when dealing with new processes or product designs.
• Analogy: Many companies can build with Legos, but Bravo Team steps in when there are no existing Legos for a specific need.
• Custom engineering opens up possibilities when standard tools cannot solve a problem.
• Examples:
  • Tooling modifications for new manufacturing processes.
  • Adding inline or end-of-line testers for new product features.

Balancing Innovation with Practical Challenges in R&D

• Balancing bold innovation with budget and time constraints is a core challenge.
• Key factors for success:
  • Customer Trust: A strong relationship and high trust level allow for more exploration.
  • Disciplined Design Process: Being a good student of the design process, avoiding early commitment, benchmarking, and understanding the IP landscape.
  • Cross-Disciplinary Team: Having a diverse team that collaborates effectively.
  • Explicit Communication: Maintaining open and honest communication with the customer about progress, level of effort, and potential challenges.
  • Time-boxed Research: Ensuring that research is focused on answering specific questions with a defined minimum level of effort.

Creating a Problem-Solving Environment

• Custom solutions offer an ideal problem-solving environment for engineers.
• Clients need to understand that custom solutions may cost more and require research.
• It's crucial to find engineers who are comfortable with uncertainty and can persevere through challenges.
• Quote: "Hardware is unforgiving. It's ruthless."
• Openness, vulnerability, and a willingness to seek feedback are essential for protecting both the team and the customer.

Automation: Current Trends and Future Directions

• The automation landscape has expanded significantly, with more companies offering controllers and product families.
• Historical Progression: Relay logic -> Programmable Logic Controllers (PLCs) -> PLCs with IO and communication protocols.
• Current Challenges:
  • Lack of a skilled labor force capable of easily modifying control systems.
  • Legacy equipment with long lifecycles (10-20 years or more).
• Future Trends:
  • Making controllers more accessible and easier to program for plant personnel.
  • Decreasing hardware costs.
  • Increased integration and higher-performing controllers with integrated HMIs.
  • More wireless interfaces between machines.
  • Greater standardization.
  • Increased use of automatically guided vehicles and AI to compress steps in workflows.
• Key Point: The future of automation depends on empowering the labor force to use the technology effectively.

Building High-Impact Engineering Teams

• Core Strategies:
  • Honesty and Transparency: Being explicit about the job requirements and expectations.
  • EOS/Traction: Implementing a management system like EOS (Entrepreneurial Operating System) to drive the business based on a clear vision.
  • GWC (Gets It, Wants It, Capacity): Ensuring that team members understand the job, want the job, and have the capacity to do it.
  • Careful Hiring Process: Slowing down the hiring process to ensure a good fit for the team, culture, and work.
  • Meaningful Work: Providing employees with meaningful work that they are empowered and capable of doing.
  • Fair Compensation: Ensuring that employees earn a high-quality wage.
  • Psychological Safety: Creating a safe environment where people can lean on each other and do their best work.
  • Learning from the Army: Setting up team members for success and removing obstacles.

Managing R&D Projects and Overcoming Roadblocks

• Key Strategies:
  • Leveraging Networks: Utilizing contacts and experts to overcome technical challenges.
  • Following a Scientific Process: Explicitly defining the problem, hypothesis, testing methods, and definition of done.
  • Proactive Action: Avoiding paralysis by identifying and taking the next steps.
  • Customer Alignment: Ensuring that the customer understands the risks, costs, and potential challenges of R&D.
  • Managing Expectations: Making sure customers understand NRE (Non-Recurring Engineering) costs.

Communication and Customer Relationship Management

• Explicit Cadence of Communication: Maintaining a regular communication schedule to manage customer expectations.
• Project Kickoff and Scoping: Investing time and resources in thorough project scoping.
• Long-Term Relationships: Prioritizing long-term relationships with customers over short-term budget optimization.
• Addressing Budget Overruns: Taking responsibility for budget overruns and focusing on maintaining the customer relationship.
• Integrity and Ethics: Upholding ethical standards and ensuring that safety and customer experience are prioritized.

Final Advice for Civil Engineers and AEC Leaders

• Continue to explore the world of engineering and design.
• Strive for excellence in your individual contributions.
• Find the joy and magic in your work and focus on that aspect.
• Key Point: Engineering is a team sport, and collaboration is essential for success.

Synthesis/Conclusion

The discussion emphasizes the importance of custom engineering solutions when off-the-shelf options are inadequate. It highlights the need for a disciplined design process, strong customer relationships, and a collaborative team environment to drive innovation and overcome challenges in R&D projects. Furthermore, it underscores the evolving landscape of automation and the critical role of skilled labor in leveraging new technologies. The conversation concludes with a call to find joy and purpose in engineering, recognizing its profound impact on the world.