As a retired aircraft engineer, I too have seen too many poor design for maintenance examples. Some of it is due to a lack of coordination in the design process and some of it is due to making manufacturing and assembly easier(and hence less costly) and both of them are nothing more than excuses for not thinking of the product being a system that is manufactured and assembled, put into service, and will be required to be maintained.
Our industry used to be an example poor integrated design at its worst. We started including maintenance people in the design process on the 777 and what a difference that made! We developed "fly through 3-D representation" and using ergonomics determined how to install components that could actually be removed and replaced without requiring a mechanic to have a couple of universal joints in each arm. We no longer had a mechanic required to change a light bulb in a passenger service unit and we went from a 24 hour engine change to under 4 hours on the 737NG.
We went from delivering a new airplane and having our airline customers try to figure out how to use it to delivering a usable product that could go into service almost immediately.. When you pay $500,000,000 for an airplane, you have high expectations! We weren"t perfect but we were a darn sight better than we used to be.
Automobile service is now a profit center for dealerships and at $100-150 per shop hour, there"s little incentive to make the modern car, with its much better reliability, easy to maintain. It took me two hours to change the left headlight bulb on our Forester. I had to take out the battery and loose other components for what should have been a 15 minute job.
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Today's Featured Article - Seeing an Old Friend - by Joe Evans. Dad had a concrete contracting business starting in 1960. One of his first pieces of equipment was a Ferguson TO-35 with a Davis loader. Dad replaced the TO-35 with a MF 202 Workbull, essentially an industrialized Ferguson 35 I am told. Dad bought the 202 new in 1962, and I recall quite clearly going to the dealer with him to sign for it.
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