PARTS COUNT
A highly effective way of improving an existing product can be to undertake a parts count when taking it apart for analysis.
If you can keep the product's functionality unchanged (or improve it) whilst reducing the number of components you can improve the product's efficiency in several ways:
- Fewer parts mean that there is less to go wrong- more complex products with more moving parts have more opportunities for failure
- Fewer parts may mean less weight- so produced in high volumes reducing the weight will have an effect on transport, meaning lower costs and pollution, even if it is only using one less bolt or rivet
- Fewer parts may result in more efficient manufacturing times- there are fewer assembly processes
- Fewer parts may result in products that are easier and quicker to maintain, repair or service
- Fewer parts means reduced consumption and processing of raw material, reduced energy costs of component manufacturing transport and recycling and less environmental impact
- Fewer components will contribute towards creating a circular economy
On the other hand there needs to be a balance maintained- you can't remove all the bolts without it falling apart (unless you find another way to hold it all together), and there may be some products where being as light as possible may actually be a disadvantage. However a parts count analysis done carefully will reveal where you can and cannot remove components.
Yet another reason to not fall in love with ideas, to be brave enough to slay the Sacred Cow, and to not be afraid to challenge previous assumptions, no matter how much has been invested into their formulation.