Why is it essential for mechanical designers to visit the workshop?

What is a Workshop Like?

In the eyes of most people, a workshop is a place filled with the deafening noise of machines, where the floor and walls are smeared with oil stains. The old, outdated equipment and apathetic workers are engaged in repetitive, monotonous tasks. The only source of any life might be a few motivational slogans on the wall—dusty and uninspiring, as if they have never been cleaned and perhaps never needed to be. After all, there are far dirtier places than the wall, which makes the slogans seem almost too clean.

In your impression, it seems there is no worse working environment than this. Just visiting is hard to accept, let alone working in such conditions for years. If you’re unlucky, it could be a lifetime of such work. It’s like a form of self-punishment, and a sense of existential doubt keeps flashing in your mind: “God, what have I done wrong?”

Now, imagine the promotional videos of those internet companies—high-end offices, and the worst part is they even have gyms and coffee lounges. The computers are the latest models, the chairs have swivel and fold functions, and the desks are always adorned with flowers and personal trinkets. What’s even more outrageous is that some companies even allow pets in the office. This isn’t work—it’s more like a vacation! Some bosses go so far as to let you choose when to work—are you working or doing charity?

For many college students today, the workshop has become a nightmare. It is a place they deeply resent, and even many people who are willing to work in or are already working in the mechanical industry dislike going to the workshop and avoid it as much as possible.

But, in fact, we need to have a deeper understanding of this industry. Modern manufacturing enterprises, while not as comfortable or lucrative as many internet companies, have made tremendous progress with advancements in technology and the widespread adoption of Industry 4.0. Many companies have made unprecedented strides in automation and intelligence.

Modern factories, clean and bright temperature-controlled workshops, and busy, tireless robots have largely replaced manual labor. Workers, now more like operators of intelligent equipment, handle what appears to be complex tasks with ease and professionalism. The labor intensity and working environment have been greatly improved. This is definitely the future trend and inevitable development for manufacturing enterprises.

Many of the factories that college students visit during internships or apprenticeships are still old and dilapidated. This is because your schools, due to resource limitations, can only connect you with such companies. Alternatively, only those companies with less technical content are willing to provide internships for students. Many advanced automated companies, due to technical confidentiality, do not allow outsiders to enter, even if they are their own employees. Unless it’s directly related to their work, they won’t allow access.

This is a common practice in many Industry 4.0 companies because the layout and processes of production are so valuable that even a quick glance can allow someone to learn most of it. However, these companies and teams, who are the pioneers in these technologies and processes, have invested enormous human and material resources to tackle these challenges. Allowing others to easily learn from them is simply not cost-effective and is not permitted.

Take Japanese companies as an example. I once spoke with a sales engineer for ball screws and linear guides in Japan. When I asked about the level of automation in the industry there, he said that when dealing with clients, they wouldn’t allow them to see the full picture of the project. They only discuss the portion they are responsible for. Entering their facilities requires special approval, and no photos or videos are allowed. There is even someone assigned to monitor your actions. (By the way, the Japanese engineer spoke excellent Mandarin, which is impressive because Chinese is such a difficult language to learn. He spoke so well that I could barely tell he was Japanese, so we Chinese people must keep striving for success—it’s not achieved overnight.)

I’ve digressed a bit and ended up in Japan, but let’s return to the main subject. Why should you go to the workshop? Why do you need to be there? This is a confusion many people have. I will explain it from two perspectives based on my own experiences.

What You Need to Learn in a Workshop

If you are in a mechanical workshop, what exactly should you be learning? Here are six key aspects:

1. Familiarize Yourself with the Capabilities and Scope of Various Machining Equipment

In a typical workshop, you’ll see equipment like lathes, milling machines, shapers, grinders, boring machines, drilling machines, laser cutting, wire EDM, etc. What operations are these machines used for? What are their processing accuracies?

It’s important to understand the cutting-edge technologies available (which can be easily accessed online) and how your factory’s machines compare in terms of their current capabilities and status. What is the state of the industry in your city? This knowledge is crucial for future product design.

2. Understand the Product Machining Processes

For example, how are the machining processes arranged? What tools and fixtures are required for each process? How are the machine parameters adjusted?

Is the machining precision in line with the drawings? How do you inspect whether the machined part is qualified, and what tools are used to perform these inspections? These are important issues that need to be thought about and accumulated as foundational knowledge, which will serve as the basis for your future design work.

3. Learn How to Operate Machining Equipment

While you don’t need to be an expert in operating the machinery, you should know how these machines are operated and understand their structure.

If you were designing the equipment, how would you improve it? Are there better structural and machining methods than what is currently in place? During the use of the equipment, you should observe its strengths and weaknesses, then absorb and turn those observations into your own skills.

4. Learn to Embrace Mistakes

Throughout your career, you’re bound to make mistakes, and reflecting on those mistakes is the foundation for growth. But making mistakes comes with a cost. Who will cover those costs for you? The workshop is where you’ll make your initial mistakes, and that’s the best place to start—because the cost is low.

If you make mistakes in the R&D phase, you’ll realize that the costs are astronomical. Many mistakes in R&D are only discovered during equipment assembly and debugging, at which point a significant amount of investment has already been made. In the workshop, however, you can usually recover from process errors, and even if you can’t, the cost is generally low and acceptable.

5. Learn to Communicate with Others

Most factory workers are naturally kind and rational communicators. They may seem a bit rough or blunt, but if you treat them sincerely, you can quickly integrate into a new work environment.

However, the innocence and sharpness from student days can be dulled by the harsh realities of the workplace. Many skilled workers may intentionally challenge fresh graduates with difficult technical problems.

This might be a common trait among technical people—wanting to showcase their skills and perhaps finding satisfaction in outsmarting a so-called “genius” graduate. While it might seem like a small victory to them, it’s important to learn how to deal with such situations with humility and grace.

6. Develop a Professional Attitude

In the workshop, attention to detail is crucial. For fresh graduates, tasks like serving tea, cleaning, and wiping tables may seem menial at first. However, this is also a way to test your attitude. Only by excelling at small tasks can you gain the opportunity to take on bigger responsibilities.

Every small task is a stepping stone to your larger goals. Before you have the ability or the opportunity to handle big projects, first learn how to complete smaller ones with excellence.

What You Should Know in an Assembly Workshop

If you’re in a mechanical assembly workshop, what should you be learning? Here are the key aspects to focus on:

1. Product Assembly Process Flow

Take a detailed look at how a product goes from scattered parts to a fully assembled device. What assembly operations are involved? What are the steps and procedures required? What tools are needed for assembly?

You also need to understand the inspection tools, assembly fixtures, techniques, and the inspection rules and processes. This knowledge will be incredibly valuable for your future designs.

2. Use and Operation of Various Assembly Tools

You should become familiar with tools such as:

  • Electric drills
  • Scrapers
  • Dial indicators
  • Straightedges and squares
  • Levels
  • Laser interferometers

Mastering these tools helps you gain a rational understanding of a product. This experience will ensure that in future product design, you can intuitively create designs that are easy to assemble, avoiding assembly interference or errors.

3. Learn to Operate CNC Systems

As a design engineer, while you may not need to be an expert in operating machines, understanding the control systems of various CNC machines is an added advantage. During debugging and testing, using the operating system is unavoidable.

Some common CNC systems include:

  • FANUC
  • Siemens
  • Mitsubishi
  • Huazhong CNC
  • Guangzhou CNC
  • KND CNC

Most of these systems have similar operating methods, so once you master one, learning others becomes relatively easy. Knowing one system well will help you quickly adapt to others.

4. Deeper Understanding of Components and Their Role in the Assembly Process

You need to gain a deeper understanding of how various functional parts and components interact during assembly, as well as the assembly steps involved.

Without this on-site assembly experience, a mechanical design engineer is not truly qualified. Just like the historical figure Zhao Kuo, who was famous for his theoretical strategies but failed on the battlefield, without hands-on experience, your design might not work in practice. Either it will be too difficult to assemble, or it won’t assemble at all.

5. Learn the “Fitting” Process During Assembly

Assembly isn’t just a process of putting parts together; it also involves “fitting” them accurately. For example, the precision and alignment of rails or the positioning of lead screws require fine adjustments that must be done on-site. The techniques and processes involved in this are difficult to understand without first-hand experience. If you lack this experience, the structures you design will likely have hidden pitfalls.

Conclusion

Working in the workshop is a process of laying the foundation. Just like constructing a towering building, the foundation must be strong for the building to stand tall. The workshop is where you lay that foundation. By grounding yourself in hands-on experience and accumulating knowledge, you’ll be prepared to tackle more complex and impressive designs in the future.

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