Managing Design Changes Late in the Process

Engineers often face a tough challenge: making design changes when an assembly is close to production. At this stage, every adjustment has consequences.

On one hand, the change is necessary. On the other, the question arises: “Who will I upset if I make this adjustment?” Large-scale changes can feel like opening Pandora’s Box, creating ripple effects across the entire assembly.

The Value of Small, Targeted Adjustments

Sometimes the best approach is to focus on small, localized changes that only affect a single part of the design. By containing the impact, you avoid disrupting the entire system.

Thanks to modern microprocessors, some changes don’t even require mechanical modifications. A simple programming adjustment can fix issues that once would have demanded hardware redesigns.

A Real Example: Robotic Vehicle Project

On a recent project involving a robotic vehicle, our analysis showed that the structural loads were too high. Instead of redesigning the mechanical components, we made a small programming change. That adjustment reduced the loads, solving the problem without touching the hardware.

The Takeaway

Design changes are inevitable, especially late in the process. But by approaching them strategically—favoring small, contained solutions—you can fix problems while avoiding costly ripple effects.

Norman T.  Neher, P.E.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org