jfoxvol
500+ Head-Fier
Yeah, when I was first hired at Sumo, they made four different amplifiers. Not one amplifier shared one part with any other amp. Literally--the chassis were different down to the screws--and the screws were spec'd down to the point of using, say, 6-32 x 3/16, 6-32 x 1/4, 6-32 x 5/16, and 6-32 x 3/8" in a single amplifier with no clearance issues that would have prevented the 3/8" being used for all. They all used different output devices. They had no commonality in passive parts or topology (one used carbon comp resistors, LOLWUT?).
The result was predictable--complete pandemonium in parts ordering (because nothing could be ganged together for lower cost), on the line (because every product was completely different from one another--experience didn't cross products), and in engineering (because everything was a unique and special snowflake, so you don't have time to apply learning from one to another.)
They asked me to present a plan to make production more efficient, about a month after I started. The summary of my presentation: I've already started making radical changes to the products to reduce active inventory and allow for commonality, and all new products will be based on similar topologies with the same output devices, even sharing chassis components.
Their response was to howl. "How can you just start making changes? We had the greatest engineers here! What happens when you start messing with their work."
My response: "Well, they aren't here now. They left a mess. Do you want it fixed, or not?"
To their credit, turned out they did. But it wasn't without some consternation in the process. In the end, we had 5 amps, all using the same output devices, in three basic chassis designs--and none with 23 screw sizes...and about an 80% reduction in active inventory items.
Carbon Comp? What are they salvaging old fender amps?