Ascending the soap box...
Ugh! I've been laying awake for two hours now and cannot get to sleep as I think about this.
You know, I've approached this subject quite a number of times over the last few months in different settings and always feel like I'm hitting a brick wall. I'm coming to discover that a different approach is necessary. You see, in order for this discussion to be a productive one we all must be willing to accept the fact that we all look at life through our own set of eye glasses often called paradigms. For example, it was believed for centuries that the earth was flat and the center of the universe, and when it was suggested otherwise, those idiots were sent to the stocks for heresy.
In fact, just today at our local RVators meeting I posed the following question: "If you could buy a certified airplane with the same performance as your RV for the price of the kit (including engine, avionics, everything) would you still build?" The resounding response from nearly EVERYONE was, "IT CAN'T BE DONE!!! THERE IS NO WAY A TYPE/PRODUCTION CERTIFICATED MANUFACTURER CAN DELIVER AN AIRPLANE OF THAT KIND OF PERFORMANCE FOR THAT PRICE BRAND NEW!!!" I didn't get the answer to my question. I didn't ask if it was possible. I asked: if it were a
REALITY would you build? You see this is a perfect example of folks being blinded by their blazing paradigm that they don't even hear the question that was asked.
We must be willing to examine our current paradigms (our perspectives of what we consider to be reality) and be open-minded about other possible paradigms.
If you are willing to do this then strap yourselves in because this might be an exciting adventure into the realms of
POSSIBILITY as we open our minds to other paradigms. If you are not willing to do this then don't bother reading any further. It will just be a waste of your time.
Its all about volume. As long as volume is low, the time and money is not going to be put into anything to bring it up to the level, and low cost of a honda accord. The Lycosaurus motor most people strongly protest is the best thing in the air for 250 and under HP is a good example. It is 1930 techonlolgy, designed to be built on 1930's era machinery. It should not be the premier motor choice, nor should it cost $20-25k to build one. If Honda or Toyota could sell as many 4 passenger Cessna 172 replacements a year as they do Accords or Camerys, we all could buy an new Toyota plane for $50-75k. I work in manufacturing, and it always boils down to volume.
This is obviously a very valid point and one which I will revisit often in the future. However, I must disagree with you on your last point. I don't believe volume is the end-all and be-all. My supposition is that the real issue is even more fundamental than volume. I bring this up now because it is my hunch that after this debate/discussion runs its course and comes full circle, I predict it will come down to this fundamental issue. My supposition is that this all boils down to
CHARACTER. Do we have the character to make it happen? Are we committed, passionate, disciplined? Where is our focus? On profits, bonuses, and stock performance? Or do we REALLY want to make a positive contribution to our human existence? (BTW, I'm not saying profits aren't important, without them you don't have a business, but where is our FOCUS?) Does our character value open-minded examination and challenging of our current paradigms? Or are we entrapped in our own prison of entrenched thinking because "this is how it has always been"? Do we have the courage to do what is right in the face of those looking out for number one? Do we value honesty and integrity? Do we value sustainability and longevity of the business? Or are we only concerned what we can get out of it while its still barely breathing? Do we punch the clock from 9 to 5 all the time thinking only about the weekend where all we do is sit on our a$$ in front of the TV? Or are we trying to make the world a better place?
Answer me this: Why is it that I get a blank stare when I ask folks in the industry about why they don't use Statistical Process Control? Why is it that "Senior" Process Engineers don't know what a Process FMEA is? (BTW, it stands for Failure Modes Effects Analysis and is a method for quantifying the things that can go wrong in the manufacture of a part).
Whoa! Now we're getting somewhere....
Here's a paradigm for ya: We've been airborne for roughly a century. 100 years ago we were in horse and buggy and yet, within 60 years, we had a man on the moon. It's been 40 years since then. What have we accomplished in the area of transportation of any REAL significance since 1968?
Tell me: Why do we still operate our factories like it is still WWII with equipment from that era? Perfectly good equipment, I understand. If you want to continue to build 40 year old designs and sell them for 3/4 million dollars. Not a huge market for that. The problem continues when we want to build newly designed jets on the same equipment.
Answer me this: Why don't we utilize tool dedication? What about specialization and it's direct impact on efficiency? How come we are not trending MTBF (Mean Time Between Failure), MTTR (Mean Time To Repair), downtime, and OEE (Overall Equipment Effectiveness) on our tools? Why are we not looking into PREDICTIVE maintenance algorithms on our tools? H.e.l.l. in many cases we're not even conducting PREVENTIVE maintenance. Just wait until it breaks and then we'll shut production down.....
Alright, here's another paradigm for ya: I liken quality assurance to a weight loss program. Deep down, everyone knows they need it. The good companies live it. The bad ones, if they survive at all, treat it like the diet of the week.
Why do we put little value on process automation? Look at the success of the automotive and high tech electronics sectors for this. Question: Can robots build better airplanes than humans?
Ooooooh! That's gonna step on a few toes there. Labor unions don't like to hear that.
How about this when it comes to pilot interface: K.I.S.S. Keep It Simple Stupid! As a student pilot I'm learning about how to lean the mixture. Dumb. Let's get out of the stone age people!!! I need 4 instruments on the panel. Tell me where I'm at and where I'm going. Tell me the health of my airplane (only need one red light for that). Tell me my airspeed. And tell me what the weather is doing. Give me a stick to go fast or slow and one to go up, down, left, and right. Give me a airframe parachute if things go bad. And for good measure give me a d.a.m.n. TV for the brats in the back..... No come on. How complicated can the flight training be in such an arrangement?
Ok, I've given you a few things to gnaw on. There's lots more to come. But, maybe........just maybe you're beginning to see the deep abiss of untapped potential I see in this industry.
I think I can get to sleep now.
