8 Taking Risks in Engineering Design: Lessons Learned from New Approaches
Discover transformative approaches in engineering design through insights from industry experts. This article delves into real-time processing, user flexibility, and AI-driven creativity among other key topics. Learn how these innovative strategies can lead to tangible benefits and smooth transitions in your projects.
- Embrace Real-Time Processing
- Prioritize User Flexibility
- Invest In Growth Opportunities
- Enhance Creativity With AI
- Demonstrate Tangible Benefits
- Plan For Smooth Transitions
- Test Ideas In Stages
- Experiment To Innovate
Embrace Real-Time Processing
One example of taking a risk with a new technology in product design was when we integrated Apache Kafka for real-time payroll data streaming instead of relying on traditional batch processing in a large-scale Workday payroll integration. The existing system processed payroll adjustments, tax calculations, and compliance reports in daily batch cycles, which caused delays and bottlenecks for a workforce of 1.8M+ employees.
The risk was shifting to an event-driven architecture where payroll transactions, deductions, and compliance validations were processed in real-time using Kafka Streams and AWS Lambda. Since this approach deviated from the batch-driven legacy payroll model, there were concerns about latency, data integrity, and system compatibility with Workday APIs.
The outcome was a 30% reduction in payroll processing time, allowing faster error detection, real-time compliance tracking, and automated adjustments before final payroll submission. Additionally, finance teams gained real-time visibility into payroll data, improving reconciliation efficiency.
The key lesson was that while adopting emerging tech carries risk, testing with small-scale deployments and validating data accuracy ensures a smoother transition. This shift reinforced the importance of scalability, real-time processing, and cloud-native architectures in high-volume enterprise applications.
Prioritize User Flexibility
One of the most challenging moments came when we developed a new design feature that we thought would streamline user experience. However, after launch, we quickly realized it was too simple, lacking the customization options our users actually wanted. This taught us that, while simplicity is important, it shouldn't come at the expense of flexibility. We learned to balance ease of use with powerful customization by involving users early in the design process. Since then, we've adopted a more iterative approach, testing features with a small group of power users to ensure we're meeting their needs before full rollout.
Invest In Growth Opportunities
One notable risk we took was investing in a major rebranding and digital marketing overhaul for our small business. At the time, our brand identity and online presence were outdated, and we faced increasing competition. Despite the substantial cost and the uncertainty of immediate returns, we decided to revamp our logo, website, and digital marketing strategy to better align with modern trends and customer expectations.
The investment involved not only financial resources but also a significant commitment of time and effort from our team. We engaged a professional design agency and implemented a comprehensive digital marketing campaign that included SEO, social media advertising, and content creation. The risk paid off as we saw a dramatic increase in online traffic, engagement, and customer inquiries. The refreshed brand and improved digital presence helped us attract new clients and significantly boost sales.
This experience taught me that calculated risk-taking, when aligned with clear business objectives and thorough planning, can lead to substantial rewards. It reinforced the importance of staying adaptable and investing in growth opportunities that align with the evolving needs of the market. Embracing this risk ultimately demonstrated the value of strategic investment in building a stronger, more competitive business.
Enhance Creativity With AI
I decided to take a risk by integrating AI-driven generative design tools into our product development process. Traditionally, our team relied on a mix of manual sketching and CAD modeling to explore design concepts. While effective, this approach was time-consuming and sometimes limited our ability to test a wide range of ideas quickly. By introducing AI-powered tools, we could generate multiple design variations in a fraction of the time, allowing us to push creative boundaries and iterate faster.
The transition wasn't without challenges. Training the team to use AI effectively took time, and we had to refine our workflow to ensure the technology complemented, rather than replaced, human creativity. Some designs that looked great in the AI-generated phase didn't always translate well into practical manufacturing. However, once we learned how to balance AI's capabilities with our expertise, the results were impressive. We sped up prototyping, improved efficiency, and gave clients more innovative solutions. The biggest lesson was that AI is a powerful tool, but it works best as an enhancement to human intuition, not a substitute.
Demonstrate Tangible Benefits
We took a calculated risk introducing drone-based thermal imaging for large commercial roof assessments when the technology was still emerging. Initially, clients were skeptical about the higher initial cost, but we demonstrated how this approach detected problems invisible to traditional inspections. On one 70,000 sq. ft. manufacturing facility, our thermal imaging identified six areas of concealed moisture that would have caused catastrophic equipment failure within months. The client avoided over $400,000 in potential damages and production downtime. We learned that adopting new technology requires both technical mastery and clear communication of tangible benefits to clients. Innovation is only valuable when you can translate technical advantages into client-relevant outcomes.
Plan For Smooth Transitions
One of the biggest risks I took in product design was introducing a cloud-based security solution for a client that had always relied on on-premises systems. The client was hesitant to move away from their traditional setup, fearing potential downtime and security gaps. After analyzing their needs, I recommended a hybrid approach, allowing them to transition gradually while maintaining control over critical data. It was a calculated risk, as any disruption could have caused major setbacks, but I believed the long-term benefits outweighed the short-term challenges.
To ensure a smooth transition, I worked closely with our team to test the new system in a controlled environment before full deployment. We monitored network performance, addressed security concerns, and provided hands-on training for their IT staff. There were initial hurdles, including compatibility issues and resistance from some team members, but our proactive support helped resolve these quickly. Within weeks, the client saw improved efficiency and a noticeable reduction in system maintenance costs.
This experience reinforced the importance of balancing innovation with careful planning. Introducing new technology isn't just about the features--it's about making sure it fits the company's needs and that people are ready to adopt it. A well-structured implementation, combined with clear communication, can turn even the most skeptical users into advocates for change.
Test Ideas In Stages
Balancing innovation with risk management has always been a delicate act for me. On one hand, I’m constantly driven to push the boundaries with new features and ideas for my language learning platform, Think in Italian. On the other hand, I’ve learned that not every idea is worth pursuing, especially if it could jeopardize the stability or trust I’ve built with my users.
One strategy I rely on to mitigate risks is to start small and test ideas in a controlled environment before a full-scale rollout. For example, when I first introduced the AI tutor feature, I launched it to a small group of users who were already comfortable with my platform. Their feedback allowed me to fine-tune the tool, addressing any potential issues before making it widely available. This approach not only minimized the risks but also ensured that I was delivering something of real value to my users.
Innovation is exciting, but it’s important to approach it with a clear plan for managing potential downsides. By testing in stages and gathering feedback along the way, I can innovate confidently, knowing that I’m reducing the likelihood of major setbacks.
Experiment To Innovate
Agility thrives on innovation, and one of the greatest lessons I've learned is the necessity of creating room for experimentation. I used to be outcome focused, and sometimes have been too cautious about putting time and energy into ideas that may or may not work. But I have learned that experimentation is important for identifying the best solutions. For example, I had my team dedicate 10% of our sprint time to investigating new tools and techniques. Not all experiments succeeded, but one did enabling us to save significant time in future sprints. As a result, I have adopted a leadership style prioritizing an experimental culture and celebrating learnings regardless of less than ideal output. It has inspired creativity and innovation among team members, helping us stay future-focused and relevant in our field.
