Buckminsterification of Design Planning. From ‘Critical Path’
Phase I, Individual
CRITICAL PATH TO ULTIMATE
IV. Realization
The whole program of realization is to be considered in the following
order, which breaks into two primary categories or phases: (A) the ini-
tial work to be undertaken by the individual prior to engagement of the
aid of associates, and (B) original and initial work to be undertaken by
the first group of associates. These two phases may be organized as fol-
lows:
A. Research and development by initiating individual — prior to inau-
guration of design action and development action involving full-
time employment of others. Inauguration of a general work pattern
as a natural pattern coinciding with best scientific procedure, to
wit:
Preliminary
Initiation of diary and notebook
Initiation of photographic documentation
Initiation of tactical conferences
1 . Comprehensive library study of accrued arts
a. Past
b. Contemporary
c. Theory of design — pertinent arts to be studied by the initi-
ating individual include:
mensuration and transformation, relative size
2. Listing therefrom of authorities available for further informa-
tion:
a. Local, personal contact
b. Remote correspondence
3. Pursuant to information thus gained, calling at suggested local
laboratories:
a. University
b. Industry
c. Setting up of informative tests for firsthand knowledge in
own laboratory
4. First phase of design assumption:
a. Consideration of novel, complex interaction unique to project
b. Preferred apparatus from competitive field
c. Design of appropriate flowsheets
5. Flowsheets submitted to:
a. Those competitive specialists who have proved helpful in
steps 3b and 3c
b. Industrial producers of similar equipment and assemblies
c. Make informative tests for closure of gaps supporting as-
sumed theory
6. Submit specifications and drawings of general assembly and
unique component parts for informative bids by manufacturers:
a. Second redesign of flowsheet based on available and suggest-
ed apparatus, price information, etc.
7. Prepare report consisting of diary of above, supported by pho-
tographic documentation and collected literature — with trial-
balance conclusions in indicated economic advantage (which, if
positive, will inaugurate Phase II)
Phase II, Collective
IV. B. Design and development undertaking — involving plural-authorship
phase and specialization of full-time associates. Consideration of re-
lationship of prototype to industrial complex by constant review of
principles of solution initially selected as appropriate to assump-
tions. Adoption of assumptions for realization in design of pertinent
principles and latest technology afforded.
1. Comprehensive survey of entire sequence of operations from
original undertaking to clientele synchronization. Realization
strategy number 1 by individual (Phase I). Realization strategy
number 2 by associates (Phase II).
a. Physical tests in principle of the design assumptions' unique
inclusions not evidenced in available data
b. General-assembly drawings (schematic) providing primary
assembly drawing schedule reference
c. General-assembly assumption, small-scale models, and
mock-up full size
d. Primary assembly, subassembly, and parts calculations
(stress)
e. Trial balance of probable parts weights, direct manufactur-
ing costs (approximately three times material costs; includes
labor, supervision, and inspection), forecast of overall cost
magnitudes, and curve plotting — at various rates of produc-
tion, ratioed to direct costs per part and "all other costs"
i.e., "overhead," tool and plant "amortization," "contingen-
cies," "profit"
f. "Freezing" of general assembly and its reference drawing
g. Drawing for first full-size production prototype commences
in general assembly, primary assembly, subassembly, and
parts
h. Budget of calculating and drawing time is set, with tactical
deadlines for each
i. Parts drawing and full-size lofting and offset patterns
j. Prototype parts production on "soft tools" commences
k. Subassembly and primary assemblies replace mock-up parts
1. Physical tests of parts and subassemblies with obvious cor-
rections and necessary replacements (not improvements or
desirables, which must be deferred until second prototype
is undertaken, after all-comprehensive physical tests have
been applied)
m. Photography of all parts and assemblies
n. Full assembly completed and inspected — cost
o. Static load tests
p. Operation tests
q. Assembly and disassembly
r. Photography of all phases
s. Packaging and shipping tests
t. Estimates of savings to be effected by special powered field
tools
u. Opinion testing
v. Final production "clean-up" prototype placed in formal cal-
culation and drawing with engineering budgeted deadlines
w. Parts cost scheduled by class A tools and time
x. Production tool layout fixed
y. Production tools ordered
z. Production dates set
a-1 Lofting and offsets produced of full-size test "masters" and
templates
b-1 Fabrication of special jigs and fixtures
c-1 Production materials ordered
d-1 Production tool-jig-fixture tune-up
e-1 Parts and assembly testing
f-1 Field operation scheduling
g-1 Field tools ordered
h-1 Distribution strategy in terms of initial logic limitations
i-1 Field tests with special tools
j-1 Field tools ordered or placed in special design and fabrica-
tion
k-1 Test target area selected for first production
Critical Path: Part Two 259
1-1 Production commences
m-1 First field assemblies with power tools
n-1 Maintenance service instituted and complaints
(1)
Alleviated
(2) Analyzed
(3) Change orders of parts instituted
o-l Plans for "new" yearly model improvement run through all
or previous steps — for original production
p-1 Cycle repeated
2. Production and distribution velocity assumption
3. Plotting the assumed progressive mass-production curbs to de-
termine basic velocities of new industry
4. Tensioning by crystalline, pneumatic, hydraulic, magnetic
means
5. Compressioning by crystalline, pneumatic, hydraulic, magnetic
means
6. Consideration of manufacturer's basic production forms — rela-
tive to proposed design components for determination of mini-
mum steps, minimum tools, and minimum waste in realization
7. Establishment of priority hierarchies of effort
8. Time-and-energy cost budgeting
9. Assumption of industry responsibility for field practices, not
only in mechanical and structural, but in economic design
10. Designing for specific longevity of design appropriate to antici-
pated cycles of progressive obsolescence and replacement ability
as ascertained from comprehensive economic-trend curves
11. Designing with view to efficient screening of component chemi-
cals for recirculated employment in later designs
12. Maxima and minima stated and realized performance require-
ments per unit of invested energy and experience, and capital ad-
vantage of tools and structures employed and devised
13. Logistics assumptions, compacted shipping considerations
as original design requirement in
(a) Nesting
(b) Packaging
(c) Compounded package weight
(d) Relationship to carriers of all types
(e) Field delivery
(f) Field assembly
(g) Field service and replacement
14. Consideration of tool techniques
15. Consideration of materials' availability
16. Consideration of materials' ratio per total design
17. Elimination of special operator technique forming
18. Elimination of novel soft-tool designing
19. Numbers of
(a) Types
(b) Repeat parts
(c) Subassemblies
(d) Primary assemblies
20. Number of forming operations
Number of manufacturing tools by types
22. Schedule of forming operations included on parts drawings
23. Decimal fraction man-hours per operation
24. Designed-in overall one-man-ability at every stage of operation
25. Schedule of design routines and disciplines
26. Establish a "parts" inventory of "active" and "obsolete" draw-
ings — from beginning
Critical Path: Part Two
27. Establish a "parts" budget of "required" designs of "parts" for
assemblies and major assembly and general assembly and molds
28. Drawing dimension standards
29. Establish a numbering system of controlled parts
30. Establish purchasing techniques, jig-and-fixture, lofting tech-
niques
C. Public relations — to run concurrently with all phases of IV (B)
1 . Education of public
Rule 1 : Never show half-finished work
a. General magnitude of product, production, distribution. But
no particulars that will compromise latitude of scientific de-
sign and production philosophy of IV (B)
b. Publicize the "facts" — i.e., the number of steps before "con-
sumer realization"
c. Understate all advantage
d. Never seek publicity
e. Have prepared releases for publisher requests when "facts"
are ripe
Similar outlines can be found here: https://wiki.p2pfoundation.net/Holistic_Problem_of_Manufacturing