Azteck’s work with clients in stimulating their design processes led to such a successful design that Azteck’s Manufacturing Improvement division scoped the ‘Winning by Design’ Innovation Award and were runners up in the Designer’s Award, ( article ).

Client Circumstances

Our clients have been manufacturers of lubricators for 60 years.  These lubricators are used on very large engines, and machinery such as compressors for trans-continental gas pipelines.  Their market position was being challenged by cheaper, less accurate and shorter-lived units from overseas.

The lubricator had to be dramatically reduced in price, while retaining the high performance, precision accuracy, exceptional long life.

Azteck’s Facilitation Processes

After technical orientation where Azteck learnt how the existing product worked and was made we, with the client, chose a small development team.  We chose the chief designer, the most experienced machinist and fitter.  The idea of bringing staff from the shop floor into the Boardroom is, sadly, an anathema for many companies.  One only has to reflect on who had the best and most practical ideas to overturn any concerns.  Sensitive facilitation is crucial: for many this will be the first time their opinion has mattered.

Some thought that we would cockily sound off about how to design hydraulic pumps.  It’s true that we picked up some hydraulic knowledge in 15 years in the Dowty Group, but that is not the point.  We started with a simple question: “What does the customer want? “.  This took 2 days to answer in full and covered the walls in flip chart pages and sketches.  While we have expertise in both computer and paper design processes, we recommend an inclusive approach that engages people eg more grounded user-friendly techniques such as flip charts.

After each 2-day session, the team were exhausted but exhilarated.  They left with an agreed programme of investigation and development for the next session in a week’s time.  In many clients, staff cannot believe that they are authorised to make something they designed.  This critical stage tests the company’s ability to trust, delegate and properly use staff at all levels.

After 2 more 2-days sessions, the prototype had been designed and full manufacturing drawings prepared.  With some projects it is sensible to by-pass much of the drawing stage and just make it.  It is refreshing how complex concepts may be fully evaluated by a skilled tradesman working to a sketch on a beer mat.  This is very very cost effective.

In 2 weeks a prototype was running side by side with its ancestor on a test rig.

Original Design	Prototype (L) on Test Rig

This process appears easy; once articulated.  A key part of the process is facilitation by an experienced independent outsider.  This gives credibility, created a fresh environment and even our ignorance is a very powerful tool.  “Sure we know nothing about lubricators, so please take me through it again …  “ is an astonishing technique when honestly applied.

Azteck’s Prototyping Resources

Unusually Azteck has its own prototyping workshops.  These are well-equipped general engineering workshops with some unusual facilities such as a metallurgical laboratory.

We also have an extensive network of tried and tested suppliers and sub-contractors.  This combines with our knowledge of suppliers of all things from ‘accumulators’ to ‘zig-zag folding machines’ to ensure that we can source practically anything.

We are most grateful to our clients for permission to publish this article.  Comments here about negative attitudes do not reflect this client’s situation.