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Most engineering mistakes in manufacturing don’t look serious at first — but they quickly turn into rework, production delays, and lost shop time on the factory floor. In this episode of Manufacturing Runs The World, we break down how one hour of rushed engineering work can realistically turn into 20 hours of manufacturing rework.
We sit down with Matthew Gettle, Mechanical Design Engineer at Reading Bakery Systems, to explain why designs that look perfect in CAD often fail in real-world manufacturing environments. Matthew shares how rushed decisions, missed details, and lack of shop-floor feedback quietly destroy manufacturing efficiency, quality, and trust between engineers and technicians.
This conversation dives into the real friction between engineering teams and the assembly floor. From food-grade sanitary design and safety standards to custom machinery and operator usability, Matthew explains why good manufacturing engineering requires more than equations — it requires real-world awareness.
If you are an engineer, designer, manufacturing leader, or student entering the manufacturing industry, this episode will change how you think about design responsibility, time management, and the real cost of engineering decisions on the shop floor.
Manufacturing Runs The World exists to challenge the idea that manufacturing is dirty, boring, or dying — and to show why modern manufacturing is technical, precise, and more important than ever.
CHAPTERS:
00:00 Why engineering mistakes cost more than you think
00:09 One hour of engineering equals ten hours of shop time
00:17 Why designs that work on a computer fail in real life
00:35 What a mechanical design engineer actually does
00:54 The hidden challenges of food-grade machinery design
01:24 Balancing sanitation, safety, and complexity
01:56 Designing for real people, not just machines
02:30 The biggest mistake engineers make early in their careers
03:04 Why shop-floor experience matters more than equations
03:36 Earning trust from machinists and technicians
04:18 Why feedback loops save time and money
05:10 Reducing design time without sacrificing quality
06:02 Preventing new engineers from making costly mistakes
07:21 How better components improve machine performance
08:00 Designing machines that actually work for operators
08:48 Why multiple design reviews are non-negotiable
09:49 Advice for future engineers entering manufacturing
10:31 The 20-hour lesson every engineer must learn
🙏 Thank You to Our Sponsors
Ellison Technologies
Ellison Technologies empowers manufacturers with advanced CNC machines, automation, and expert support — helping shops work smarter, faster, and more competitively.
https://ellisontechnologies.com
GSC – 3D & Automation
A leading reseller of SOLIDWORKS CAD software and Markforged industrial 3D printers, empowering engineers with cutting-edge design, simulation, and additive manufacturing tools.
Your support helps keep conversations about manufacturing, engineering, and leadership alive.What part of the engineering process do you think causes the most rework in manufacturing today?
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