On Aug 8, 4:18 pm, Terry S <[email protected]> wrote:
> Sometimes these efforts save the company millions. Other times they
> don't save money at all or even end up costing the company money when
> things go wrong. Overall, the 2nd set of eyes and hands generally
> makes the product better and more reliable. Not always at first, but
> inevitably the effort pays off and the company is better for it. When
> I contribute to such an effort, I indirectly share in the savings,
> thru increased margins, profit sharing, stock price, etc.

And sometimes they cost the company millions. Three words: "RA81 glue
problem"

There is often a tendency for good engineers who worked for a large
company to go "into the weeds" when they form their own company to
make similar products. In one example I'm very familiar with,
engineers who worked for a company named I left and formed company E
to make disk drives. They contracted with manufacturer T (a very well-
respected name) to produce stepper motor driver hybrid modules. There
was a near-90% incoming inspection failure rate on these modules, and
the rest failed after they were installed on pre-production drives and
shipped. The company I was a partner in, P, was E's second-largest
customer, behind company D.

I decided I needed to sort things out by flying to E's California
location to see what was going on. Their engineers explained that the
drives were failing due to the very-complex hybrid modules. I said
something like "why don't you just use a quad Darlington IC instead?"
After an extended period of "ummm... errrr...", they agreed that this
might be a good idea, and their chief designer and I sat down to draw
out the re-design that night. He had to fight to get approval to build
a test batch of the redesigned boards, since others in the company
were deeply invested in the original hybrid version. I still have one
of the first 10 drives with the re-designed board (it probably still
works, but there is no use for 40MB ST506-interface drives these
days), as well as a bunch of the non-working hybrid-based logic
boards. By the time E ramped up production of the drive, D had
cancelled their purchase contract and E turned into a disk platter
supplier and was subsequently purchased by another drive manufacturer.

[Company names shortened to the initial letter to protect the innocent
(and the guilty)]

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