Instead of simply pointing out a design flaw, a senior engineer prompted a junior to create a machining plan for their part. Through this exercise, the junior engineer personally discovered the impossible undercuts. This Socratic questioning approach is a powerful teaching tool, as it forces self-realization and critical thinking.

Designers should consider the human operators and machines that will assemble their product. By making choices that simplify manufacturing—providing clear instructions and avoiding known difficulties—the process becomes smoother and more efficient, akin to 'riding a bike downhill.'

An engineer with deep project involvement develops tunnel vision. Bringing in a senior engineer who is unfamiliar with the project allows for high-level pattern recognition and questions about fundamentals (like manufacturability) that the core team may have overlooked while deep in the weeds.

A common Design for Manufacturability (DFM) error is specifying features like tiny chamfers or internal cuts that look feasible when a part is magnified on a CAD screen. In reality, these features are often physically impossible for a tool to access or create, necessitating direct communication with the machinist.

To ensure a smooth transition from development to production, an operations or manufacturing SME must be part of the design process from the start. Otherwise, products are developed without manufacturability in mind, leading to expensive, reactive fixes and subjective quality control during scale-up.

Individuals who learn a trade through hands-on experience, rather than a formal degree, often have a less rigid, "un-boxed" approach to problem-solving. They aren't constrained by prescribed step-by-step methods, allowing them to see alternative paths to the same result that formally educated engineers might miss.

Unlike purely theoretical coursework, programs sponsoring real industry problems allow students to build applicable skills. An engineer designed a fuel cell test station for a senior project, which directly led to an internship where his first task was to recreate that same project, proving the value of practical experience.

At American Housing Corp, engineers who design components also manufacture them in the factory and assemble them in the field. This forces them to experience the "pain" of their design decisions firsthand, creating a rapid, visceral feedback loop that leads to faster and more effective product improvements.

Founders in CPG should personally master the hands-on production of their product before outsourcing. This deep knowledge of the process is invaluable, equipping you to ask specific technical questions and properly evaluate a co-manufacturer's capabilities, ensuring quality is maintained at scale.