Simple Manufacturing
Here at AK Studios we try to utilize the design principle K.I.S.S.
Below is a great post Griffin Kirby put up on our Instagram explaining the term.
K.I.S.S
“KISS” is a design principle used by the U.S. Navy. Aircraft engineer Kelly Johnson coined the term when he asked a group of design engineers to design a jet aircraft that could be repaired using only a handful of tools, tools that were commonly found in the field. Making sure that the aircraft could be repaired by an average mechanic in the field. Simplicity should be a key goal in design. Unnecessary complexity can lead to misunderstanding, misuse, frustration and countless hours trying to fix those complexities. #akstudios #lessismore #simple #design #KISS #usnavy #designiseverywhere #simplesolutions #designthinking #enduser
KISS applies to all aspects of design, but today we’re talking manufacturing. A very common problem that clients have with their products is a lack of DFM or Design for Manufacturability. Prototypes are sometimes designed solely for function/utility which is OK but at some point the product will need to be redesigned for the applicable manufacturing processes. At AK Studios we’ve found that it’s a lot easier to keep manufacturability in mind throughout the process.
So how can you keep your manufacturing simple, and why is it so important? We always preach to keep it simple and if you can afford to, keep it local. Understanding, and testing materials and fabrication methods is something we try to tackle early on in the development process. Simple manufacturing keeps the process smooth and limits the inevitable bumps. All manufacturing processes have a range of complexities in which they allow, but they are many methods of manufacturing which are inherently simpler. Typically the longer a process has been around the cheaper, and easier it is to utilize. This idea of heirloom manufacturing methods falls in conjunction with material selection. Natural materials that have been used for products for hundreds of years will typically have cheaper tooling costs compared to most synthetic materials. Projects will often die when it comes to the cost of tooling for manufacturing.
It’s certainly true that the raw cost of synthetic materials are often quite cheap when compared to natural materials.(The raw material cost for an Aluminum can is about 25-30% higher than a PET bottle of a similar volume, according to analyst Uday Patel at consultancy Wood Mackenzie). But when it comes to keeping it simple, you’ll often find working with natural materials, and manufacturing methods that have been around for centuries you’ll have less complications, and a lower initial cost to begin production.
Designing around simple manufacturing is different for every product and situation. That means understanding the volume you’re looking to (or able to) produce, the material requirements of the environment you’re designing for, and your user base. Having that knowledge early on can enable you to design for more affordable manufacturing processes. As a general rule of thumb the longer the manufacturing process has been around the cheaper it will be. I understand that every project is different and some require the unique and impressive capabilities synthetic materials, and complex manufacturing method provide, but if you can K.I.S.S, then you should.
Want to learn more?
Both of the following books I consider indispensable for anyone who would like to design and actually manufacture products.
Check out Making It: Manufacturing Techniques for Product Design by Chris Lefteri
