Michael Filler and Matthew Realff discuss Fundamental Manufacturing Process innovations. We explore what they are, dig into historical examples, and consider how we might enable more of them to happen. Michael and Matthew are both professors at Georgia Tech and Michael also hosts an excellent podcast about nanotechnology called Nanovation.

Our conversation centers around their paper Fundamental Manufacturing Process Innovation Changes the World. If you're in front of a screen while you're listening to this, you might want to pull up the paper to look at the pictures.

Key Takeaways

1. Sometimes you need to go down to go back up
2. The interplay between processes and paradigms is fascinating
3. We need to spend more time hanging out in the valley of death

Links

Fundamental Manufacturing Process Innovation Changes the World(Medium)(SSRN)

Michael on Twitter

Matthew Realff's Website

Michael Filler's Website

Nanovation Podcast

Topics
- The need for the innovator to be near the process
- Continuous to discrete shifts
- Defining paradigms outlines what progress looks like
- Easy to pay attention to artifacts, hard to pay attention
- Hard to recreate processes
- The 1000x rule of process innovations
- Quality vs price improvements
- Process innovation as a discipline
- Need to take a performance hit to switch paradigms
- How to enable more fundamental manufacturing process innovations

Transcript

[00:00:00 ]

this conversation, I talked to Michael filler and Matthew Ralph about fundamental manufacturing process innovations. We explore what they are, dig into historical examples and consider how we might enable more of them to happen. Michael and Matthew are both professors at Georgia tech and Michael also hosts an excellent podcast about nanotechnology called innovation.

Our conversation centered around their paper called fundamental [00:01:00 ] manufacturing process. Innovation changes the world, which I've looked to in the show notes and highly recommend the fact that they posted it on medium. In addition to more traditional methods, give you a hint that they think a bit outside the normal academic box.

However, I actually recommend the PDF version on SSRN, which is not behind a paywall only because it has great pictures for each process that I found super helpful. If you're in front of a screen, while you're listening to this, I suspect that having them handy, it might enhance the conversation. And here we go.

the, the place that I'd love to start is, to sort of give everybody a, get them used to both of your voices and sort of assign a personality, a personality to each of you. so if each of you would say a bit about yourselves, and the. The, the sort of key bit that I've loved you to say is to, to focus on something that you believe that many people in your discipline would sort [00:02:00 ] of cock an eyebrow at because clearly by publishing this piece on medi you sort of identify yourself as not run of the mill professors.

 

Oh boy. Okay. So we're going to start juicy, real juicy. So I guess I'll go since I'm speaking, this is Mike filler speaking. Great to be here. so I've been a professor of chemical engineering at Georgia tech for a little over 10 years now. my research group works in nanoscale materials and device synthesis and scale up.

So for say electronics applications, Yeah. I mean, this article, which we'll talk about emerged from, you know, can I say a frustration that I had around electronics really is where it started for me, at least, that. We have all this focus on new materials or new device physics or new circuit. And I know your listeners are probably thinking about morphic computing or quantum computing, and these are all very cool things, but it seemed to me [00:03:00 ] that we were entirely missing the process piece.

The, how do we build computers? and, and, and circuitry. And, and so that's where this started for me was, starting to realize if we're not dealing with the process piece, that we're, we're missing a huge chunk of it. And I think one of the things is that people, people miss that where within working within the context of something developed 50 or 60 years ago, in many cases, and it's it's was really hidden to a lot of people.

And so that, that was where I came at this. Great. All right. So, yeah, so I'm, also a professor of chemical and biomolecular engineering at Georgia tech. my background is actually in process systems engineering. And, if you go back to the late 1960s, early 1970s, actually frankly, before I was a much more than in shorts, there was a, that was a real push towards.

The role of process systems engineering in [00:04:00 ] chemical engineering in it really arose with the, with the advent of computing and the way that computing could be used to help in chemical engineering. And then slowly over time, the, the role of process systems engineering has become, I think, marginalized within the chemical engineering community, it's gone much over towards.

What I call science and engineering science in a way from the process systems piece of it. And so, you know, as Mike would, would berate me with the, with his travails over, over what he was trying to do with nano integration and nanotechnology, I realized that what he was doing was describing a lot of the same frustrations I felt with the way that process systems engineering was being marginalized and pushed to the edges of chemical engineering with the.

Focus more around fundamental discoveries rather than actually how we translate those fundamental discoveries, into, functioning, processes that then lead to outcomes that affect society. So for me, it, it, it [00:05:00 ] was a, it was a combination of, talking to Mike and then my own frustrations around how my own field was somewhat marginalized within the context of chemical engineering.

Got it. And, sort of to, to anchor everybody and, and start us off. could you just explain what a fundamental manufacturing process innovation it's. So the way we think of fundamental process innovation or manufacturing process innovation is actually rethinking how the steps in a process are organized and connected together.

And so that has become the paradigm which we have. we have set for fundamental manufacturing process innovation, and these innovations come in in different categories that enable us to put these processes together. And one of the examples of which for example, is. I'm factoring taking something that has been done together at one process step and separating it into two different steps that occur maybe at different [00:06:00 ] times or in different places.

And by so doing, we actually enable us to make, a tremendous change in the way that that process operates. So it's really around. The strategy for organizing and executing the manufacturing steps and using a set of schema is to sort of understand how over history we have been able to do that. Do you want to add to that mic?

Yeah. I want to take a step back outside of manufacturing. So one of the examples we give at the outset of the piece is not in manufacturing, but in shopping something that every single person listening to this can wrap their mind around, I think. and I still love the example cause it just kind of. I miss it every single day.

and this is all pre COVID thinking of course, but the idea that say a hundred years ago, and a lot or Western societies, you would go to let's call it the general store. and you'd walk in, go up to the counter. And, if I have a list maybe, and you'd handle lists to the purveyor, and they would go [00:07:00 ] in the back rows of shelves and they'd pull off what was on your list and they'd bring it out to you, you pay for it and you go on your Merry way.

And then, you know, several decades ago, this started to change, probably half century my ex ex ex. Exactly sure. The timing, but, to, to a model, where instead of a single shop keeper, having to interface with many individual, shoppers, it was now many shoppers who did the traversing of those aisles themselves, right?

This is at least in Western society is what we are familiar with today as the grocery store or the target or the Walmart. And what you do is you. Trade one thing for another in doing that right. Instead of, the person, the, the purveyor, getting things for you, which from a customer's perspective is very nice.

Right? you, you, you no longer have that, right. You're being told. Okay. He used to, yeah, he or she used to get it for you now. You're going to go and traverse the ALS yourself. But you do get something in return as the [00:08:00 ] shopper. And that is a lower costs because now one store at the same time can be, open to many, many people stopping shopping simultaneously.

So, selection goes up, costs go down and there's a benefit for the customer, and the shopkeeper. So this is an example of a process innovation it's the