Revolutionizing Manufacturing Through Design Thinking: A Success Story

In the ever-evolving landscape of manufacturing, where efficiency, cost-effectiveness, and innovation are paramount, harnessing the power of design thinking has emerged as a game-changing strategy. This methodology, which originated in the realm of product design, has proven to be an invaluable tool in transforming manufacturing environments, yielding remarkable results. In this article, we’ll delve into a real-world success story from my professional experience that showcases the incredible potential of design thinking in manufacturing.

The Power of Design Thinking in Manufacturing

Design thinking is a human-centered problem-solving approach that emphasizes empathy, creativity, and collaboration to generate innovative solutions. Its core principles have found resonance in a variety of industries, with manufacturing being no exception. The essence of design thinking lies in its ability to break down complex challenges into manageable segments and then reassemble them into innovative solutions. By focusing on the needs of end-users, it drives the creation of products and processes that are not only functional but also deeply meaningful.

The Double Diamond Method: Navigating the Innovation Journey

A shining example of design thinking’s transformative potential in manufacturing is the application of the “double diamond” method. This approach involves four distinct phases: Discover, Define, Develop, and Deliver. Each phase has a specific purpose, guiding teams through a structured yet adaptable process.

Discovery: Unveiling Opportunities

The journey begins with the “Discover” phase, where teams immerse themselves in understanding the problem at hand. This is the time to gather insights, empathize with end-users, and uncover unmet needs. By tapping into the collective wisdom of team members and stakeholders, a deep understanding of the challenge is developed.

Definition: Crafting a Clear Path

Once armed with insights, the process advances to the “Define” phase. Here, the focus shifts to synthesizing the information collected in the discovery phase. The aim is to identify the core problem to be addressed and craft a clear problem statement. This step ensures that the team is aligned and poised to generate innovative solutions that resonate with end-users.

Development: Unleashing Creativity

With a refined problem statement, the “Develop” phase comes into play. Creativity takes center stage as teams brainstorm and ideate. This is the stage where the magic of design thinking truly shines, as diverse perspectives collide to generate novel ideas. Prototyping and testing are key components here, allowing for rapid iteration and refinement of concepts.

Delivery: Bringing Innovation to Life

Finally, the “Deliver” phase marks the culmination of the journey. The innovative concepts developed in the previous stages are refined, finalized, and brought to life. Effective implementation strategies are devised, and the transformative solutions are integrated into the manufacturing process.

A Triumph in Manufacturing

In a tangible demonstration of design thinking’s prowess in manufacturing, consider the case of a company that sought to optimize costs and enhance efficiency. The problem started when we looked at the financial implications of staff accidentally forgetting a temperature probe to check the temperature of the material, as required by quality assurance, inside a mixer. These probes are wireless and small, and adding the fact that this process needs to be done on every batch of product at early mornings or odd times exacerbated the issue.

Through the application of design thinking’s double diamond method, a team pioneered the creation of a cost-saving mechanism. Using advanced tools such as SolidWorks and a 3D printer, the team harnessed their creativity to devise a groundbreaking solution. This solution not only exemplified technical prowess but also addressed the needs of the end-users.

By focusing on empathy and collaboration, the team created a mechanism that seamlessly integrated into the manufacturing process. The result? An astounding $35,000 in savings per facility per year, translating to an estimated total savings of $1.2 million. This success story highlights how design thinking can revolutionize manufacturing by aligning innovation with practicality. One key element of their innovative solution was to introduce a wired thermometer with a holder using 3D printers, effectively eliminating the issue of staff forgetting temperature probes and ensuring the required quality checks were consistently met.

Unlocking Potential Through Design Thinking

As manufacturing landscapes continue to evolve, the application of design thinking emerges as a beacon of innovation. By nurturing empathy, fostering collaboration, and celebrating creativity, this methodology transforms challenges into opportunities. The case study of the cost-saving mechanism stands as a testament to design thinking’s transformative power in manufacturing. As we move forward, embracing the principles of design thinking promises to unlock a world of potential, shaping the future of manufacturing one innovation at a time.

About the Author

Afthab Azeez is a highly skilled Manufacturing and Design Engineer at Walinga Inc., specializing in developing manufacturing processes for customized trucks and trailers. With expertise in Lean Manufacturing and Design Thinking, he optimizes production processes and implements cost-saving mechanisms. Alongside his industry experience, Afthab has a strong background in teaching and mentoring, having taught Design Thinking and Calculus at Carnegie Mellon University. He holds advanced degrees in Engineering Design from McMaster University, Automobile Engineering from Amity University, and a bachelor’s degree in Mechanical Engineering from Mahatma Gandhi University. Proficient in tools like SolidWorks and Creo Parametric, Afthab delivers exceptional results with his critical thinking, effective communication, and strong leadership skills. Outside of work, he enjoys oil painting, stop-motion animation, and polymer clay modeling, adding a creative perspective to his engineering problem-solving.

Looking to build your creative, critical and design thinking skills? McMaster University Continuing Education’s unique Creative, Critical and Design Thinking program equips learners with the tools to succeed by enhancing your ability to solve intricate problems.