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Engineering Flashbacks - They design it, we fix it...

Gonzo

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Gonzo Grand Master

Gonzo

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Engineering Flashback

Let’s just assume you’re one of the engineers who designs part of the modern automobile. Your job is to follow the guide lines and concept ideas the other engineers have put together. All you have to do is make whatever component or section you’re assigned fit into the space provided. You also have to keep the cost down and keep in mind the design restraints. Then, make sure it can be manufactured in such a way it can easily be installed and sent down the assembly line at the quickest pace possible.

I’m sure it’s a nerve-racking job. So much pressure is put on you to come up with something that will work, easy to assemble, and cost effective. You’ve strained your brain to come up with something, worked long hours to design it, built the prototype, and checked the results. You’re positive it will work. Now, it’s all up to the guys and gals on the assembly line to get it put together and out the door.

This time around, let’s pretend you’re the consumer. You’ve checked out this latest model and it’s just what you were looking for. It’s got the right styling, the right size, and it’s in your price range. So, you buy it. Ya take it home and enjoy the comforts of owning your brand new car. Then, several years go by. You’ve almost got it paid off and hoping for a few years without car payments. But, all of a sudden you’ve got car problems. You’ve followed the maintenance schedule to the letter, but something has still gone wrong. It’s out of warranty, which means it’s not going to be free, but you’ve got to get it repaired. You can’t fix it; in fact you don’t have any idea what is wrong. But, your favorite mechanic will. So, it’s off to the repair shop to have it diagnosed.

Let’s change gears again. Now we’re the mechanic. You get the car into the shop, you run the needed diagnostic tests, and find out that a little bitty part buried behind the dash has failed. The only way to get to it is removing the entire dash. Before diving into the nuts and bolts side of it, you’ve got to call the customer. This is not going to be an easy call, because you know the labor cost alone is not going to make for a happy car owner, for sure. You give them the figures for the R&R and there is a moment of gasps and shock. Then, reality settles in, and the owner tells you to go ahead with it.

Now, we’re back to being the engineer. Reports start coming in about how this little bit part that you designed and stuck inside the dash is failing left and right. The amount of backlash from all these repairs from all over the country are flooding your desk. What can you do about it? Probably nothing. Other than not designing anything like that again. So, you keep your head to the grindstone and persevere. Onto your next project. But, the memory of that little bitty part behind the dash haunts you day and night. In fact, you might even have flashbacks of the numerous reported failures, and you certainly don’t want to relieve that again.

This time around you’re asked to design a similar system on the latest car from the concept team. Those flashbacks of that little bitty part you stuck behind the dash is still fresh on your mind. This time, you’ve changed the design a bit so that same issue doesn’t happen again. Or, at least you hope not.

We’re back to being the consumer again. This time you’ve done your homework and looked at the new models to replace your present car. You’ve also kept in mind that huge repair bill for some silly little bitty part that could have been easily repositioned somewhere else. You’d like to avoid anything like that on your next new car. You talked in great detail about it to your salesman and he assures you there isn’t any problem like that anymore. If anyone would know about the inner workings of the modern car it would be the guy selling it to you right? With the salesman’s stamp of approval you write that check for your new car, and off you go to enjoy your new ride.

It’s the mechanics turn to return to the mix. That new car is now a few years old and it’s having problems. This time it’s a different problem than before, but the cost of the repair is even higher. It seems our engineering friend forgot to think of how many things are overlapping and concealing the components he designed. Simple things like changing a headlamp bulb require an afternoon at the repair shop. The anti-lock brake system is incorporated with the cruise control. The air conditioning system is aware of the exhaust fumes from the car in front of you and automatically regulates the fresh air dampeners. Radar systems, GPS, and so on and so on. Nothing is even remotely simple anymore, and nearly everything costs more than it should. The mechanic has to spend even more time in training classes keeping up with what the engineers are designing, as well as dealing with the next shock and awe from the customer over the price of repair.

And you wonder why a mechanic rolls their eyes back in their head when you bring a car in with a certain type of problem. Yep, they’re having flashbacks of pulling the dash to get to that little bitty part.

The flashbacks of these engineering designs continue. I don’t know about you, but I think the only person who might really know what’s happening in the real world when it comes to your car is the mechanic. The consumer has to pay the bill, the engineers try their best to design it, and the salesman does what he does. It all adds up to job security for the mechanics, they’re the ones keeping those little bitty things behind the dash working. In all honesty, the consumer might want to ask a mechanic about that new car or even used car they’re planning to purchase rather than the salesman or the engineer. They’re the ones who deal with the aftermath of the salesman’s claims and the engineer’s designs.

The engineer, the consumer, the salesman, or the mechanic. Who’s going to have the most flashbacks of these design debacles? Well, for me, it’s the mechanic. They’ve got to deal with the problems created by the engineering, the customer, and the salesman. Now, if the engineers wanted to really find out something about their little bitty part behind the dash, just put a few mechanics in the same room with a few of those engineers. That might make for one colossal flashback they’ll never forget.


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after6tuning@aol.com Contributor

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If you have ever done an evaporator on a Mercedes S class from the early to late 90s w140 chassis (ie: 95 s500) you will be astonished at the engineering and the ammount of things you have to do to get it out. I believe it used to pay 24hrs or something like that. I have done one and can almost guarantee I will never do one again.

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Gonzo Grand Master

Gonzo

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It all comes down to cost versus profit. When I worked at Chrysler we did evaporators in Trucks and Grand Cherokees with regualarity. When I asked an engineer at a training class why they didnt change the design I was told the cost of repalcement was still below the cost of redesign.

So, it's cost effective design it crappy and let us mechanics deal with the aftermath? Nice.... thanks engineers for the work and the ticked off customer who has to pay for your lousy design. Which of course, the customer thinks we're the ones ripping them off. Where's that engineer at? .........

Vdubfixer Rookie

Vdubfixer

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I've always kinda wanted to punch the engineer responsible for the lock rings on Beetle headlights...

It's no fun telling the customer that it's going to be at least an hour and they need a new lock ring for a light bulb that's probably like 10 minutes or less by the book.

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Andre R Enthusiast

Andre R

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Had to do an evaporator on a Saturn Vue. By the time I got it out there was nothing between the back seats and the firewall. The center console came apart in 8 pieces. Just finished a flasher on an 02 vette. Have to remove the top part of the dash because the flasher comes out the back.grrrrr

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      The Technician Shortage Is Our Fault, And It's Time We Own It
      Nearly every day, I hear shop owners complain: "There's a technician shortage. We can't find qualified people. There's no one out there." If that's true, then who's to blame?
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      In this blog article, I will break down the key reasons we are in this situation today and what we, as an industry, can do to solve the technician shortage. Are you ready to look in the mirror?
      Have We Pushed Technicians Away?
      Let's take a look at flat-rate pay. True flat rate, which pays a technician only for the hours they produce, is a controversial pay plan that emphasizes high production levels and creates a competitive work environment that, if not properly controlled, can lead to increased mistakes and a decline in morale and team spirit. Additionally, the stress and physical demands placed on technicians as they age are not favorable to long-term employee retention. What do we do with technicians as they grow older into their fifties and begin to slow down? 
      I have heard all the arguments and pros and cons of flat-rate pay, and I am not going to judge any pay plan. Let the facts speak for themselves. True flat rate has changed in most areas around the country and has evolved into a pay plan that gives technicians some pay guarantee.
      Many shop owners have learned that team morale, along with the opportunity to earn income, is important to technicians and to the company's long-term success. But let me ask you: how many technicians have left or been pushed out over the years because of the old flat-rate pay system?
      Another issue is the workplace environment. I remember being grateful to be hired as a young technician at a local repair shop. While very thankful, the work environment was not ideal. The shop owner kept the bay doors open year-round (I am from New York) unless it rained or snowed. He felt that if the bay doors were closed, customers might think we were closed for business. We had no heat and no hot water. Many of the jobs were done outside, year-round,  in all types of weather. The starting pay was minimum wage, with no benefits, sick days, or vacation pay. 
      Now, again, I need to point out that I was truly grateful for the opportunity this shop owner gave me. I learned a lot working there, and the experience was pivotal in my career. But looking back, I wonder how many people were discouraged by these working conditions?
      While the physical demands of the repair workplace are daunting, perhaps even more critical is the culture. Too many of my generation shop owners preached the mindset of "my way or the highway." We were the business owners, after all. We started our companies, took all the risks, and provided jobs. Why shouldn't we be the ones to set the ground rules our way?   
      Many of us found over the years that the "my way or the highway" mentality was a sure way to isolate employees and make them more likely to look over the fence for greener grass. In other words, it led many technicians to seek employment elsewhere, where they felt they could be appreciated and recognized for their hard work. The issue, however, was that there wasn't much green grass around. Disappointment after disappointment, bouncing from repair to repair shop, eventually led to despair. So, I ask you: were workplace conditions a contributing factor in today's technician shortage?
      Another factor that we are all well aware of is the complexity of the modern automobile. When I started, the work was mostly physical, and you were required to master essentially three vehicle models: General Motors, Ford, and Chrysler. Let's fast-forward to today. The evolution of automotive technology, along with the extensive training and tools required, has outpaced the typical technician's pay compensation, with no clear career path. Again, leading to frustration and insecurity about the future.
      Here is the bottom line: people don't leave their job; they leave their experience. We must do a better job. 
      The News Isn't all Bad; Your Next Steps to Fix the Technician Shortage
      To fix the technician shortage, it will take a combined effort from everyone in the automotive industry, particularly automotive shop owners. Shop owners are in the perfect position to make the greatest impact, not only on their businesses but also on the future automotive workforce.
      First, shop owners must become better leaders and understand that their ultimate success is directly dependent on the people they assemble around them. Any shop owner who mistakenly believes they can build an empire solely on their abilities is destined for serious disappointment. Business owners who think like this will eventually plateau. Without the collective contributions from a team of qualified people, your business will stall; it will not continue to grow.
      Create a workplace that attracts top talent: a clean, professional, well-equipped facility designed to support productivity, teamwork, and a career, not just a job. Build a great reputation in your community by getting involved locally. Become the auto repair shop that people take notice of as "the" place to work.
      Next, shop owners must become more financially knowledgeable. Knowing your numbers and what you need to achieve for a strong bottom-line profit is essential to paying technicians the money they need and deserve. Profit will also allow you to compete with other trade industries by providing a benefits package that has real take-home value and security.
      When it comes to culture, this is where the rubber hits the road. People crave recognition, praise, and a sense of purpose. Despite what you hear, people are not just money-motivated. Once people feel secure in their financial situation, retaining and motivating technicians can only be achieved by connecting with them on an emotional level. You cannot show enough appreciation. Give out praise for a job well done as if your business depended on it, because it does.
      As technicians age, we need to have a place for them. Expecting a 58-year-old to perform like a 35-year-old is unrealistic. We need to be more focused on career pathing. Provide training, skill development, and coaching to develop leaders and mentors within our older workforce. While their bodies may have slowed, the knowledge they have gained is priceless. 
      Our future is dependent on young people entering our industry. We need to give more young people opportunities. Every shop owner across the country should consider hiring an apprentice, then build an apprentice training plan and career path for them. If every shop did this, we could solve the technician shortage within five years. Get involved with the trade schools and high schools in your area. Look into the NAPA Apprenticeship Program. Don't sit on your hands with this one. Do it today.
      Lastly, don't get left behind. Commit to ongoing training for all your employees. Keep up to date with tools and equipment tailored to your business model. Don't try to be all things to all people and all vehicles. Identify your core profile customer and the vehicles they drive, and become an expert on those vehicles and the services you offer.

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