Mechanical engineer: how to work faster?
Mechanical engineer: how to work faster?
(OP)
I am a mechanical engineer in a wood sawmill company, I am designing various machines. I use solidworks for my design. The problem is this: I am not satisfied by the speed I design things. Here are some aspects I analyzed and noticed:
1. I always try to make the model as "full" as possible - including all bolts, chains, and anything else. This is essential for generating BOMs correctly, and also avoiding design mistakes due to things that were "imagined" differently than they really are. Any decrease in model detail would result in more mistakes (previous engineers, like 3-4 people have perfectly showed how not designing something leads to the need of fixing the final product with angular grinder in the workshop, making much more mess than use). I don't think I can save anything here.
2. I use all the productivity tools: keyboard shortcuts, best-practice design tools and strategies, PDM, fast hardware computer, two monitors, 3d mouse, I know the software deeply (including that I have passed several SW certificates). I don't think I can increase anything the speed here.
3. I have a fair amount of experience in the things I design - I don't have to spend too much time on the phone consulting the suppliers, or the machinery guys/welders to make the design better, and so on. I mean, I don't get stuck often during the design. I don't think I can do anything faster on this.
4. Of course, there are times when I have to do the research: check the solutions of the competitors, consult the suppliers about the things I haven't used before, perform FEA simulation, etc. Also, I sometimes have to explain things to the welders/machinery guys/assembly guys - about what have I designed and what is the intent of those solutions. But - obviously - I will never know everything, and so these communications will always be needed. I don't think I can rapidly save any time here.
Besides, I think I can say that I make fairly little amount of mistakes. I check, and I check, and then I check things again. I must admit I lose some time here (absolutely not significant amount of time, but it adds up a little), but design mistakes would make much, much longer to fix during the manufacturing process compared to the model, so I wouldn't like to risk the increased amount of the mistakes for winning a few hours on design checks.
That being said, I feel stuck in the situation. Even a fairly simple machines takes 1-2 weeks or more to design, and when I look at the finished model - and I can't believe it took that much time. I have no idea how can I make it faster.
If anybody here, the more experienced engineers, could share their productivity strategies, that would be great. I am pretty sure I can not win anything on the software level (as I said I think I can say I know Solidworks fairly well), but maybe some global design strategy could be used to save a few percent of the overall design process.
Thank you for your advice
1. I always try to make the model as "full" as possible - including all bolts, chains, and anything else. This is essential for generating BOMs correctly, and also avoiding design mistakes due to things that were "imagined" differently than they really are. Any decrease in model detail would result in more mistakes (previous engineers, like 3-4 people have perfectly showed how not designing something leads to the need of fixing the final product with angular grinder in the workshop, making much more mess than use). I don't think I can save anything here.
2. I use all the productivity tools: keyboard shortcuts, best-practice design tools and strategies, PDM, fast hardware computer, two monitors, 3d mouse, I know the software deeply (including that I have passed several SW certificates). I don't think I can increase anything the speed here.
3. I have a fair amount of experience in the things I design - I don't have to spend too much time on the phone consulting the suppliers, or the machinery guys/welders to make the design better, and so on. I mean, I don't get stuck often during the design. I don't think I can do anything faster on this.
4. Of course, there are times when I have to do the research: check the solutions of the competitors, consult the suppliers about the things I haven't used before, perform FEA simulation, etc. Also, I sometimes have to explain things to the welders/machinery guys/assembly guys - about what have I designed and what is the intent of those solutions. But - obviously - I will never know everything, and so these communications will always be needed. I don't think I can rapidly save any time here.
Besides, I think I can say that I make fairly little amount of mistakes. I check, and I check, and then I check things again. I must admit I lose some time here (absolutely not significant amount of time, but it adds up a little), but design mistakes would make much, much longer to fix during the manufacturing process compared to the model, so I wouldn't like to risk the increased amount of the mistakes for winning a few hours on design checks.
That being said, I feel stuck in the situation. Even a fairly simple machines takes 1-2 weeks or more to design, and when I look at the finished model - and I can't believe it took that much time. I have no idea how can I make it faster.
If anybody here, the more experienced engineers, could share their productivity strategies, that would be great. I am pretty sure I can not win anything on the software level (as I said I think I can say I know Solidworks fairly well), but maybe some global design strategy could be used to save a few percent of the overall design process.
Thank you for your advice





RE: Mechanical engineer: how to work faster?
Do you have a good library of parts? Do you use a lot of similar parts so could set up a more fleshed out template that automatically adds certain views or similar?
Do you have any standard calculations set up in matlab or excell or... so you can just plug the appropriate numbers in?
How much time do you spend on other stuff? For instance I have a few standard meetings that suck up my time more than you'd think. I also get involved in supporting quotes that takes up my time too.
How much of your time is spent on non work productive stuff like checking Eng-Tips (speaking of which gotta go...
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Mechanical engineer: how to work faster?
Chains: yes, I model it fully. I need it for the exact length, I usually need a precise length of the chain. Besides, newer version of SW has the "Chain component pattern", which makes the design of the full length chain pretty simple. Besides, I often need special attachments on the chain, so I can't simplify anything here.
Library/templates: yes, it is set up. Standard parts are in the library (bolts, washers, bearings, and everything else). I don't want to go too deep here, but trust me - I have spent a fortune of time optimizing it and now it works fine and fast, and I can't make it any faster.
Calculations - yes, I use SMath - small program, which makes calculations more handy and easier (consequently - faster) than excel. When I have a new project - I use a file from previous project, adapt it, change numbers and make it work. Don't think can make anything faster here.
I use zero (none, absolutely) of my time on web browsing. I never have an unproductive meetings because I work alone - I design machines that my boss tells me to.
I sometimes discuss things with welders/machinery men about how to make the things better, and they often have good suggestions. So these discussions often lead to actually saving time on the long run.
I use Epiforge Grindstone to track my time. I clearly see that I don't have any unrelated activities, but the time it takes to design things make me suspicious that it should be possible to make some things faster... If only I knew how :)
RE: Mechanical engineer: how to work faster?
I am sure that some guys cut corners and get away with it, but not my style either.
"Of course I don't look busy, I did it right the first time"
= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, Plymouth Tube
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
Well, I guess we now know that to be not entirely true (a little sharp edged humor, EighthBen, not malicious!)
Depending on the complexity of the machine, several weeks does not sound at all unreasonable. It's far better to be thorough and take an extra hour or two to prevent a mistake that may take days to fix, as you have said.
How have you come to the conclusion that you are taking too long? Is it by feedback from boss/supervisor, offhand comments by someone else, knowledge that someone else in a similar position performs more favorably?
It is better to have enough ideas for some of them to be wrong, than to be always right by having no ideas at all.
RE: Mechanical engineer: how to work faster?
It takes X number of keystrokes to draw a line and there's no 2 ways about it. It sounds like the only way to reduce time on a project/part is to review your design process. I'm not in the business of designing parts of cars with solid works, but something that helps me in designing HVAC and piping systems is to put pencil to paper before I even turn the computer on. (I can draw a line on paper a lot faster than I can in AutoCAD.) Once that's done, I'm less likely to move a line or block 20 times in CAD. The most useful tools I use are the triangles from my college days, a pencil and sketch paper with a scale and calculator not far behind.
Also, start putting together a library of what you've done in the past. I'm sure there are plenty of blocks and details (or whatever SW calls them) you can use from one job to the next, re-use them. (I'm sure you're already doing this to an extent, but find more.)
Take notes when talking to the welders, machinists, assembly guys and keep those notes at your desk. Ask them how you can make plans more understandable and do it. Drawing it once so they understand the first time is better than drawing it twice and having to explain your design in person.
At the end of the day, what works best for me is not what will work best for you, you will need to find a process that works best for you.
RE: Mechanical engineer: how to work faster?
ornerynorsk: I mean I must use maedler.com, chiaravalli and other catalogs, find out how some things are calculated, and other things on the net. But I never read news or otherwise spend time during working hours.
dbill74: Yes, I sometimes do that, as much as paper allows it. But maybe I should to it more, because I edit thing quite a lot before I come to final design.
Library - yes, I do it, there are certain automation tools to reuse things in Solidworks and I make the best of it.
Notes: yes, I write a journal with the notes I get from welders and other workers and also a separate journal on how to make a design in the best way in Solidworks. I use them to remember the best practices that worked out.
As you see I tried quite a few things but I am still not satisfied with my speed. I believe the biggest brake is my lack of experience. So I came here to discuss if this could be partly overcome faster than naturally working in the field for years.
RE: Mechanical engineer: how to work faster?
You seem to know a lot of the fine points of design and your design tools (e.g. SolidWorks). That's a good start, but it seems like you lack a framework for defining and starting a project and moving it through its stages of development. (At least you didn't think enough of it to mention.)
Perfection is rarely worth its price. There is such a thing as good enough. Does a miscount on hardware stop the whole show while someone flies 200 miles to buy it? Or do they get more from the bin? Are you holding up long-lead things like steel purchasing while you count your nuts?
RE: Mechanical engineer: how to work faster?
1) Your 'touch time' while you're actually working on the project i.e. man hours not calendar weeks.
or
2) Total length of time of the project?
You imply 1 but thought I'd check.
Re. not modelling in all hardware, yes for one off or low volume work or similar may not be worth the effort for the sake of BOM accuracy etc. but...
Can be useful in things like making sure you have adequate clearances (Been bitten here when I didn't realize some rivet heads weren't modeled in) or even mass calculations etc. As well as clearly showing where it goes on drawings or work instructions or...
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Mechanical engineer: how to work faster?
Were I hired as a consultant** for your problem, the first thing I would work on making a complete survey of what the final output is required to be like, what the type of input ordinarily given is, and what steps are required going from one to the other. Then we could look at what you think can go faster/ is currently unsatisfactory. When that flow is understood it's possible to see useless tasks and eliminate them and to look at characterizing the amount of time spent on the major tasks with an eye to both entire steps plus any common functions that are repeated across steps.
No different than any software performance analysis.
For example: I originally took 3 weeks to do a swept-volume analysis with a wire-frame/surface modeler. Then decreased that to 1 week with a bit of software I wrote. The third go around was going to be a day or less, but it required understanding the process to move from one speed to the next.
**I don't consult for anyone, so I'm not advertising.
RE: Mechanical engineer: how to work faster?
Often there are numerous simple parts that similar across several products and these are often drawn individually, when a simple table drawing would define all possible configurations. How hard is it to find previously design parts that will do the job. I once worked where they designed subsea jumpers that used large numbers of straight and single bend tubing, they redrew the lot for each project because they used such a poor naming / part numbering convention that you couldn't find them. A couple of table drawings could have replaced the lot.
The first 5% of a programs efforts locks in about 80% of a program costs (number may vary but you get the drift), more focus on the design concept at the start might reduce the project time length.
RE: Mechanical engineer: how to work faster?
Why do you feel spending 40-80 engineering hours to do a professional job designing and modelling a piece of machinery is excessive? Is your employer telling you that you need to work faster? Or are the machines you design incredibly simple devices, or slight modifications of existing products?
Consider that since we now rely heavily on the fidelity/accuracy of digital CAD models for functions like analysis, QA, manufacturing, etc, it is very important to make sure the CAD model is 100% accurate when released. Better to do the job right than to do it fast.
RE: Mechanical engineer: how to work faster?
It's the Pack-and-go command. Do you use it often?
When designing machines in SW most part types used will be common and thus used in previous projects too.
There are sheet metal parts (flat, angled, U shape, Omega shape, Z shape and such), rigid parts like round bars, profiles (not the design library parts!), hollow tubes, square tubes and so on. Parts based on extrudes and parts based on revolves etcetera.
So it is a handy trick to use packandgo with replacing the part/drawing numbers and thus quickly generate a new part-drawing combination. Then modify the part dimensions and use it in the new machine assembly.
Benefit is that in the background the attached part drawing is automatically updated. Once the parts are done (many features added like holes or deleted) and you like the assembly design you only have to clean-up the already attached part drawings.
RE: Mechanical engineer: how to work faster?
Finally, and without wanting to appear negative, if you work quicker what will you do with the time you have saved?
RE: Mechanical engineer: how to work faster?
You call yourself a machanical engineer but you are not!
You are an assistant planner, an assistant purchaser and an assistant outsourcer and also an engineer.
This may sound silly but I read you use PDM.
Synonyms for PDM more often than not are: time-consuming, frustrating, bookkeeping, redundant, managers toy, innovation kill and so on.
In other words: look to the finished model with the eyes of a purchaser, a planner and an outsourcer as well.
Their time gain should be added to your engineering time frame!!
RE: Mechanical engineer: how to work faster?
When you design machinery, or anything else for that matter, there is a certain amount of overhead work required to keep you organized. People pressuring you to speed up will tell you to not bother with this, and they will speed you up, in the short term.
I have repeatedly seen people complete mechanical design, and hand manufacturing a stack of fabrication drawings. They may have saved quite a bit of time by not bothering with assembly drawings and BOMs, but...
- ...manufacturing generated BOMs. Overall company effort was not saved.
- ...manufacturing took control of the drawings and BOMs. There was no point trying to reason with engineering, so they didn't. I hope any engineers reading this are cringing.
- ...the designs were atrocious. There was no attempt to view the completed system and do DFMA, or to visualize the structure, or to visualize how the system would be managed by the end user. The top level drawings are needed by manufacturing, and they are needed for design reviews and communication with other members of the design team.
This kind of bungling is harder to do with 3D CAD like SolidWorks. Then again, the parametric modelling provides all sorts of opportunities for screwing things up.unless you absolutely have to. How much detail do you need on your chain? Each and every link probably is excessive.
Can you copy and paste from you BOM into your requisition forms? All that effort up from can save a lot of time downstream.
--
JHG
RE: Mechanical engineer: how to work faster?
For example, one thing I commonly do in SW is to start with basic geometry sketches in which I will try to establish as many of the dimensional parameters as possible for the complete part within one or two sketches, maybe on the top and front planes. I leave those sketches alone and do not absorb them into Extrudes or Revolves. That makes them easier to access later. Then for the Extrude or Revolve sketches I use the Convert tool or relations to link as many parameters as possible to those basic geometry sketches. My philosophy is simple - minimal required changes to achieve the results. If I change something I want everything else affected by that change to change along with it.
I also commonly rename features according to their function, for example instead of "ExtrudeCut14" it will say "Machining_for_Gearbox_Base".
Just some thoughts...
RE: Mechanical engineer: how to work faster?
Don't add unnecessary detail. For example, helices are hard on your video card. Don't model these unless you absolutely have to. How much detail do you need on your chain? Each and every link probably is excessive.
--
JHG
RE: Mechanical engineer: how to work faster?
For low volume work, the typical implementation of things like DFx, FMEA and all the other PLC alphabet soup tends to add quite a bit of overhead burden while having limited pay back.
I am not saying you shouldn't have any process, I'm saying they need to be the right processes implemented at the right scale and probably be quite flexible.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Mechanical engineer: how to work faster?
Welcome to the "Do it Right the First Time" Club. I assert that it ALWAYS takes someone longer IN THE SHORT RUN to do things if they: a) do it so that it won't need to be redone later and
b) spend the setup time it takes to make the next design go well and go quickly.
Of course it takes longer to do something in the short run. But in the LONG RUN you will win out with optimum processes, all the right information at your fingertips, and an efficient, methodical, thorough and sufficiently-documented approach.
I like to work this way but inevitably the "results by next quarter" management fixation does not reward long-run efficiency and a strong professional infrastructure (built over time) that produces robust, well-documented designs meeting all requirements and cost goals.
It is a damn shame how managers know to the minute how long it took to turn out a first design revision but do not have the maturity or desire to quantify how long it takes to fix a problem (e.g. missing dimensions, outdated industry standards, over-simplified drawing views, missing but necessary details) and revise the design until it is buried deeply in the production process (or with the customer) where it is so painful, expensive, embarrassing and time-consuming to fix. In their minds all this downstream work is just the cost of doing business. There are always people who do things "quick and dirty" who are richly rewarded. Rarely is a guy rewarded for preparedness and doing the job right the first time even if he can turn out better designs faster in the long run. I've been caught in the aftermath of so many "quick and dirty" types and it's no fun sweeping up behind them.
If anyone out there knows of a business that has such maturity and foresightedness please get my contact information from my profile and tell me who it is (confidentially of course). I want to work there!
Tunalover
RE: Mechanical engineer: how to work faster?
-Dave
NX 9, Teamcenter 10
RE: Mechanical engineer: how to work faster?
However, you make a good point kudos to the OP for appearing to be diligent and conscientious about doing a good job first time.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Mechanical engineer: how to work faster?
One of the dangers of engineering design is that everyone wants to push off their documentation to your drawings. They want "one document to rule them all".
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
PS - I definitely see the need to improve the interface of this forum for better quoting possibility ...
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
Yes, I take the advantage of it when appropriate. Furthermore, there are functions in PDM like "Move tree" and "Copy tree" - sometimes even better than PAG.
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
I don't know what are you talking about. PDM is a file management system with lots of useful functions. It definitely is NOT time-consuming, frustrating or anything else negative. Furthermore, it is actually inevitable.
RE: Mechanical engineer: how to work faster?
Additionally sounds like a design review step after you have your general concept but before you get too far into details may be a good idea.
Thinking about details early on isn't a bad thing as it can avoid costly re-designs later to address 'details' but, ideally you shouldn't invest too much time in details that might change as the design process progresses.
BTW, all those quotes could have been in one post - not sure why separate posts.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
b) I should think more about the setup and design strategy before starting the design project. I agree, I will think how can I do it. Thank you for the advice.
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
After spending much effort on analyzing my work and it's efficiency for the last week, this is exactly what my conclusion is. Those three steps may be the (only?) key to improve the efficiency of my work. This discussion have surely helped me to crystallize this. Thank you again for participating in it.
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
What do you and your boss think a good amount of time to design one of these machines would be? With your current design process what level of complete are you at that time? Is the machine able to be manufactured at that level of complete considering an acceptable amount of questions from the shop?
Another thought, are there other examples in the industry of similar items being designed in the time frame that you and your boss are hoping for? If yes, then either they begin manufacturing at a different level of completion than you, or they have a better design process then you. If there aren't any other examples, then maybe you and your boss have un-realistic expectations for yourself.
RE: Mechanical engineer: how to work faster?
The Mythical Man Month (Brooks)
Death March (Yourdon)
RE: Mechanical engineer: how to work faster?
je suis charlie
RE: Mechanical engineer: how to work faster?
It depends on what you are designing. A mechanism or action can easily be shown as a pencil sketch. Most of my messy design problems come from having to stuff something into limited space. I start designing with whatever scale tool I have, be it drafting board, 2D&nhsp;CAD or 3D CAD. A preliminary 3D model can be whipped up very quickly, and then inspected and reviewed. Usually, it is worthwhile to model several design concepts, especially if fabrication is going to cost a lot more than engineering.
If you want to do DFMA or any other fancy engineering technique, you need to start off and investigate several design concepts.
--
JHG
RE: Mechanical engineer: how to work faster?
RE: Mechanical engineer: how to work faster?
I agree with your approach of using sketches/layouts/spreadsheets/simulations to optimize a new design prior to expending engineering resources constructing a high fidelity digital CAD database. Modern digital CAD databases use a complex system of relationships and links between files, and if the parent models are not constructed with care it can cause lots of problems and rework later on.
However, in my experience a process of "design, test, repeat..." is not normal practice. Testing costs money and takes time. Instead the design is validated by analysis, and then if required the analysis work is validated by qual testing. It's more like, "design, analyze, repeat until the analysis confirms the design meets requirements.....then if required conduct qualification testing to validate analysis work."
RE: Mechanical engineer: how to work faster?
Cheers
Greg Locock
New here? Try reading these, they might help FAQ731-376: Eng-Tips.com Forum Policies http://eng-tips.com/market.cfm?
RE: Mechanical engineer: how to work faster?
A lot of model iteration is communication with co-workers.
"That's not what I meant."
"Ooh, that's cool, but how about this?"
"Oh, is that really what it winds up looking like?"
"Wow, you can do that? That lets me do this..."
Many years ago, a manager asked me something, and I quickly free-hand sketched up a mechanism. It worked, and the manager announced that we should do all design like that. I was horrified. Usually, I am stuffing lenses, mirrors and beamsplitters into a tiny space. The available space usually is my primary design problem, followed by figuring out how people are going to get at stuff.
I am designing furniture here at home. Sometimes, I start with a free-hand sketch. Sometimes I go straight to LibreCAD. It all depends on what I do not understand yet.
--
JHG
RE: Mechanical engineer: how to work faster?
Sketches? CAD? Pah.
I needed to make a camera filter adapter, and walked out to my garage, and found a piece of acetal that looked about right. Started whittling on it with my lathe, messed up the threads twice, ended up with a too-short piece of acetal (thus verifying the cut-twice measure once principle), redid the whole thing in PVC, realized that I'd not be able to turn the i.d. without clamping on my just-completed threads (home mini lathe jaws too short) and had to come to use the big lathe at work. Turned the i.d. at work based on memory of what the diameter needed to be to slip over my scope, came home and checked, found was off by about .01", back to work, home again, there we go.
Design by messing around, I think it's known as "puttering".
RE: Mechanical engineer: how to work faster?
I believe for the first part we are disagreeing mainly on semantics as analysis is usually considered a significant part of the overall design process.
A lot of model iteration is communication with co-workers.
I would suggest that one of the biggest challenges in life is communication. Realistically though, if you are losing more than an hour or two a week (~2-5% of your time) early in the design phase then I would recommend you do what is necessary to address that issue. Both lean and agile philosophies have some useful tools from daily standup meetings to task boards not to mention all manner of project management software to assist with this. Nobody lives in a perfect world, but miscommunication shouldn't drive "a lot" of work on anybody's part.
RE: Mechanical engineer: how to work faster?
I am not arguing that my co-workers are uncommunicative goofs. I am arguing that as the mechanical designer, I do not know everything. The requirements of electronics, optics (in my case), manufacturing and the end user must be taken into account. This means communication.
My book on DFMA (Boothroyed, Dewhurst, Knight) has a graphic that shows that engineering affects about 70% of the cost of the product. In reality, this value should vary wildly. In the case of the OP, it might be on the low side, given that it is one-off plant equipment.
How about we estimate the total cost of manufacturing all of the product, and budget some percentage of that for engineering? If the total manufacturing cost is high, the designers should take the extra time, do extra analysis, and try several alternate designs, and look for ways to be clever. If the manufacturing is relatively cheap, then engineering must work fast. It would be a good idea to select relatively expensive, reliable components to eliminate as much debugging as possible.
--
JHG
RE: Mechanical engineer: how to work faster?
The guys I admire, and really should try and emulate more, are the ones that manage to refine the basic problem to some mathematical relationship(s) and crunch through that. Now like I said a lot of my problems are softer geometry related issues but still should do better.
Something to look out for is applying the wrong/inappropriate model of project management or design process or whatever as I alluded to early.
Some philosophies that may make sense for say software when the '0' & '1' can be re juggled relatively quickly with almost immediate results may not make sense for hardware projects where you need to design, document, produce tooling for the part then make the part....
Philosophies like fail fast, fail option may perhaps make sense used correctly. However, when failing for entirely predictable reasons like tolerance stacks or similar the I'm sorry but it's no longer engineering by any measure - more the puttering Btrue mentioned.
What is Engineering anyway: FAQ1088-1484: In layman terms, what is "engineering"?