Step Function Solution Concept in New Product Development
Step Function Solution Concept in New Product Development
Introduction – Solving a Problem
The purpose of this article is to present the “Step Function Solution Concept” (approach) as it applies to the resolution of engineering problems. Moreover, it is intended to avoid the “continuous improvement” and corporate waste associated with maintenance and warranty issues related to unresolved failure modes. Generally, in the realm of corporate product development, there are infinite opportunities to encounter myriad issues. Hence, these can be defined as obstacles between the intended product content and successful production. Simply stated, engineers work tirelessly to define and resolve “engineering problems.”
Overall, among all the potential tools and methods available, one stands out as not fully embraced—the Step Function Solution Concept (designing out of the failure mode). In many cases, and in many engineering problems, certain design or business constraints guide the problem solver within a “box,” offering limited opportunities to develop a solution set to address the issue. However, the Step Function Solution Concept offers an opportunity to think outside of the “box”. It can generate competitive ideas that will definitely design out of the defined failure modes and solve the given issue. Consequently, this approach not only enhances problem-solving efficiency but also promotes innovative thinking and long-term success.
Step Function Solution Concept Definition, as an Application / Method / Approach to the complex problems Development of the Solution Set
In this context, and applying it as part of the Systems Engineering approach, the following is a simplified definition: The Step Function Solution Concept is a method of developing the solution set for the defined problem (with understood failure modes), which will generate a new design (elements) of the total assembly and completely solve the defined failure modes. In other words, it involves designing out of the understood problem definition by creating an alternative design.
Therefore, this approach is particularly effective in addressing complex problems where traditional methods fall short. Moreover, by thinking beyond the conventional “continuous improvement” strategies, the Step Function Solution Concept offers a transformative approach that not only resolves existing issues but also anticipates potential future failures. Consequently, this method provides a more robust and sustainable solution, enhancing overall system reliability. Transitioning to this concept can lead to significant reductions in corporate waste and long-term warranty issues, thereby fostering innovation and efficiency within the product development cycle. The application of the Step Function Concept ultimately leads to more resilient and effective designs, ensuring that the final product meets high standards of performance and reliability.
The Graph - Representation of the Step Function Solution Concept
Basically:
- The Axis x – represents time, also “Initial Condition” before the design change
- The Axis Y represents the options generated.
Therefore:
- The “Green” line is the Step Function Solution set with 100% of the failure modes resolved
- While, the “Yellow” line represents the easiest Solution Set approved for the design fix, and “Red” represents the resultant fluctuation of the unresolved warranty related to the “implemented” assembly design
- “Yellow” is shown just above the X-Axis just to show the difference between the implemented solution set and the initial condition
Part of the Problem-Solving process of Options Generation
Within the various methods of engineering problem solving, the steps of root causing and problem definition are followed by the generation of design proposals intended to address the issue. It is a proper approach to look at various potential solutions, not just one.
However, as many in the industry know, due to various factors and in an attempt to resolve whatever issue is at hand, it is very often that just one and the most obvious solution set is looked at and then implemented.
Hence, the Step Function Solution Concept is proposed for “out of the box” thinking and preparation related to the next milestone product development opportunity. Moreover, these opportunities include model year changeovers, new model development, purchasing resourcing with new supply chain contracts, and other possibilities, including ongoing time frames if feasible.
Consequently. by embracing the Step Function Solution Concept, engineers can develop a more comprehensive solution set that thoroughly addresses failure modes and optimizes the overall design. Therefore, this method promotes innovative thinking and ensures that multiple avenues are explored before settling on the final solution, leading to more robust and effective engineering outcomes.
Finally, Options Generation will be addressed in a separate article.
Step Function Solution Concept - Discussion
The argument here is not to simply:
- Fix with what is available, which often involves limited design resources and cost impacts
- Improve the existing condition, shifting from an unacceptable number of failures to merely “acceptable” levels (see example below)
- Monitor and react by making decisions based on incoming warranty or recall data and opting for the easiest solution set
- Allow for the wear of cheaper elements and provide service to the customer by opting for the easiest (cheapest) fix without fully addressing the root cause
Instead, the Step Function Solution Concept aims to completely resolves the failure modes associated with the problem. Overall, emphasizing the easiest solution set may initially seem cost-effective but can lead to long-term repercussions. Such as: increased warranty claims, reduced customer satisfaction, and overall business profitability.
Furthermore, by prioritizing comprehensive solutions that design out failure modes entirely, engineering teams can mitigate risks and ensure sustainable product performance. Essentially, this approach not only enhances product reliability but also optimizes operational efficiency and customer trust.
Therefore, transitioning to the Step Function Solution Concept represents a strategic shift towards proactive problem-solving in product development, aligning with broader business objectives and ensuring long-term success in competitive markets.
Long-term Warranty Issue Example
The following is an example of the long-term warranty issues that plagued GM vehicles in the early years. Historically, one of the most notable problems was the persistent brake fluid leak. It remained unresolved for an extended period. However, despite numerous attempts to rectify the issue, GM struggled to find a definitive solution, resulting in significant dissatisfaction among their customers. Generally, over time the issue became more frequent and widespread, affecting a large number of vehicles.
Therefore, GM’s initial response involved replacing the affected components under warranty. However, it proved to be a temporary fix rather than a long-term solution. Furthermore, the repeated repairs and replacements frustrated customers, who were looking for a permanent resolution. Fundamentally, the certain fraction of the joints was affected and the number of them remained fluctuating over the years.
Moreover, the issue had a substantial impact on GM’s reputation. Therefore, the associated warranty repairs led to increased maintenance costs for vehicle owners. Consequently, customer trust in GM’s reliability and quality was severely eroded.
Furthermore, the brake fluid leak issue serves as a historical reference to the challenges faced by automakers in maintaining long-term warranty commitments. This underscores the importance of addressing such problems promptly to preserve customer loyalty and trust. Finally, the issue remained on top of the list of the annual warranty costs allocated to Service function.
Notes: Corporate Constraints in Handling the Brake Fluid Issue
Overall, the fundamental root cause of the issue was in the long-term association between the OEM and the closest Tier I. Consequently, once the Tier I was separated and declared bankruptcy, followed the OEM’s transition into a new business unit, the issue was eventually resolved. The problem was never looked at from the “out of the box” thinking or Step Function Solution Concept. The costs related to this Warranty issue proved to be enormous and contributed to the company’s problems before bankruptcy in 2009.
However, a different supplier and consequently different design of the joint / interface between the rigid and flexible brake fluid lines was implemented on the GM trucks Colorado / Canyon models in the same time frame, starting from MY 2006 forward. These models did not have brake fluid leak issues from the get go. The Step Function Solution Concept was executed based on the learnings from other vehicle models, resulting in the development of the successful joint and its integration into the total vehicle assembly.
Conclusion - Step Function Solution Concept
In conclusion, the Step Function Solution Concept represents a paradigm shift in engineering problem-solving. It emphasizes the creation of comprehensive solutions that address root causes rather than merely treating symptoms. Generally, unlike traditional approaches that may focus on quick fixes or incremental improvements, the Step Function Solution Concept advocates for a bold redesign of products to completely eliminate failure modes. Consequently, by thinking “outside the box,” engineers can innovate new designs that not only meet but exceed customer expectations for reliability and performance.
Moreover, the strategic application of the Step Function Solution Concept extends beyond immediate problem resolution. It fosters a culture of proactive engineering, where challenges are viewed as opportunities for innovation and improvement. Furthermore, this approach not only enhances product quality and durability but also reduces long-term costs associated with warranty claims and customer service.
Therefore, embracing the Step Function Solution Concept aligns with sustainable business practices by minimizing environmental impact and optimizing resource utilization.
Finally, by investing in robust design solutions upfront, companies can avoid the cycle of reactive maintenance and costly product recalls.
Ultimately, the Step Function Solution Concept empowers engineering teams to deliver products that set new benchmarks in reliability and customer satisfaction. Therefore, it encourages continuous learning and adaptation, ensuring that future iterations of products are even more resilient and competitive in the market.
In summary, the Step Function Solution Concept is not just a methodology but a philosophy that drives excellence in product development, positioning companies for long-term success in an ever-evolving industry landscape.
References:
- Step Function – https://en.wikipedia.org/wiki/Step_function
- Engineering Change Request – https://georgedallen.com/engineering-change-requests-ecr-new-best-practices/
- Theory of Change – https://georgedallen.com/theory-of-engineering-change-in-new-product-development/
- Explain the Concept Clearly – https://www.useloops.com/blog/how-to-explain-a-concept-clearly-and-concisely
About George D. Allen Consulting:
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