[1] https://en.wikipedia.org/wiki/The_Goal_(novel) [2] https://www.goodreads.com/book/show/17255186-the-phoenix-pro...
In the novel, you get to see the characters bang their heads against these "paradoxes" again and again until it sinks in.
Weird how things that seem to make sense in one context seem to make no sense in another context. If you told me a factory runs their widget making machine at 70% capacity in case someone comes along with an order for a different widget or twice as many widgets, at first glance think that's a bad idea. If your customers can keep your widget machine 100% full, using only part of the machine for the chance that something new will come along seems wasteful. And through cultural osmosis the idea of not letting your hardware sit idle is exactly the sort of thing that feels right.
And yet, we do this all the time in IT. If you instead of a widget machine told me that you run your web server at 100% capacity all the time, I'd tell you that's also a terrible idea. If you're running at 100% capacity and have no spare headroom, you can't serve more users if one of them sends more requests than normal. Even though intuitively we know that a machine sitting idle is a "waste" of compute power, we also know that we need capacity in reserve because demand isn't constant. No one sizes (or should size) their servers for 100% utilization. Even when you have something like a container cluster, you don't target your containers to 100% utilization, if for no other reason than you need headroom while the extra containers spin up. Odd that without thinking that through, I wouldn't have applied the same idea to manufacturing machinery.
Because it is. My brother works in industrial manufacturing machinery supplies. I can assure you the overwhelming majority of manufacturing machines on the planet are not only run constantly but as near to 99.999% as possible. So much that they are even loath to turn them off for critical maintenance rather preferring to let the machine break down so they don't get blamed for being the person to "ruin productivity"
This book sounds like one of those flights of fancy armchair generals are so found of going on.
Perhaps it works in small boutique shops making specialized orders but that is a slim minority of the overall manufacturing base. I could see why the advice would appeal to HN readers.
And yes, a lot of manufacturing doesn’t behave this way. That’s the “counter” part of “counter-intuitive” revealing itself.
This comment is yet another of these excellent cases in point!
You really don’t see how “they’re afraid to turn them off even for critical maintenance” might be actually suboptimal behavior in the long run?
Why waste that 20%?
Because if the tool breaks and scratches a $200K Lexus, then that might be a $20K fix, or possibly even starting from scratch with a new body! Is that worth risking for a $5 drill bit they buy in boxes of 1,000 at a time? No.
Then the interview switched to some guy in America looking miserable complaining how his bosses made him use every tool until breaking point. He listed a litany of faults this caused, like off-centre holes, distorted panels, etc...
And you wonder why Tesla panels have misaligned gaps. Or why rain water leaks into a "luxury" American vehicle!
If tomorrow Ford decided to start this process it would be a decade before the market believed that hey had changed their ways. Would they survive this gap? IDK the new ford Mach-E is not selling so I doubt it but I"m not an economist. People don't buy fords because of the reliability. They buy it because it's cheaper and the risk of downtime is less important to them than the price premium. Don't forget that in order to achieve that lost resource return you must be disciplined all the time and most people/corps cannot achieve that.
Toyota makes some of the cheapest and some of the most expensive cars on the market. They don't "use" their reputation to do this, their reputation is the result of excellent production.
You're missing the point with Ford, which is an example of another very successful manufacturer who uses similar techniques/philosophy as Toyota, which are not similar to what your brother's machine shop does.