I have plenty of experience in production. I have set up production lines… in the US and in China.
I have trained production staff.
And clearly , I Understand production better than you do because you imagine that engineering and production can be perfected before the fact thru FMEA’s
Sorry- you give your argument away when you qualify your statement by saying “we can weed out most potential issues”-
that’s the entire point Most is Not all. And WHY initial production runs are always part of product development.
Let’s say your FEMA weeds out 99% of issue in a product that has 300 assembly steps. That leaves 3 issues you won’t solve.
THOSE are the 3 issues your early adopters will discover… because your self confidence in your abilities means you don’t KNOW you only caught 99%- by definition, you can’t solve a problem you didn’t foresee.
And how do you foresee problems in production? well, because you have experience producing things.
GM can tool for a new car and probably foresee 99.9% of potential issues and solve them before production commences… but that is only because a “new” car is still 99.9% identical to the prior car they made.
When it comes to engines, suspension, cabin, etc- the methodologies are well understood thru HUNDREDS of iterations over a century of practical experience.
But when you are building something entirely new- the chances that you can foresee all issues drops significantly.
Oh- you’ll have no trouble producing the bezel- its not that different than every other bezel…but genuinely new assemblies using entirely new parts and materials are another matter.
Now- try doping all this and Complicating your production by the fact that YOU aren’t producing anything. You have no factory. You are subcontracting the production to a factory owned by someone else- thousands of miles away and who doesn’t even speak your language.
Because that is how nearly ALL electronic products are manufactured today.
I have developed product in China- its a rockfight to get them to address the problems I CAN foresee.
I have provided Chinese companies with specifications on specialty equipment they need to use to reliably produce a product- only to visit the factory and discover they are doing it by hand,
This is why your optimism reflects an unrealistic expectation. It is why, despite your imagining that things Can be done better, that ALL companies producing groundbreaking technologies are fielding products with problems and why missing shipping projections on new products is ENDEMIC in the high technology and software worlds.
Its why Boeing and Northrup and Lockheed Martin can NEVER bring in a single product without cost overruns. because as the complexity of any product increases, the ability of human beings, no matter how clever, to foresee every potential problem decreases.
I didn’t buy the Form 1 because I KNEW it was going to be a learning experience for formlabs.
And I waited until the Form 2 was out a year and guess what? I still got a lemon because of an issue at their manufacturing plant that gave them a container full of faulty printers that they only discovered when users tried running them.
I wanted an Audi TT because in 2004 it was the only car with a dual clutch autoshift transmission. But I figured I had better wait until 2005 to let them find out what they didn’t figure out in their in house testing.
2005 Audis with the DSG transmission suffer half as many transmission issues as the 2004 model.-
Real world Use informs changes in design and manufacturing. That is why intelligent engineers and designers consider it a part of product development,