Problem: Models of batch process showed way to increase throughput by 300% . Group Think: A process run for 31 years was already optimized, little left to improve . Enabling idea (by DB): Split batch and keep reactor full . Problem with idea: at one point in optimized concept liquid would solidify and fail to…

Problem: Tool changes diameter with rpm (steel grows under tension) causing scrap . Group Think: Steel growing under tension is impossible to avoid by design changes . Enabling idea (by DB): Use balanced design for zero growth . Problem with idea: Original design unstable over rpm range . 2nd enabling idea (by JT): Shrink and…

Problem: Could not design product concept for security film that blocked photocopying . Group Think: If you can see it, you can photocopy it without detection . Enabling idea (by DB): use light-sensitive chemicals in film layer to change color and block image . Problem with idea: Didn’t possess any such chemicals or know which…

Problem: Foam with protective chemicals doesn’t penetrate carpet far enough . Group Think: Getting penetration to 100% was thought to be impossible . Enabling Idea (by AK): Add vacuum source on back side after coating . Problem with idea: Blocked by patent . 2nd enabling idea (by DB): Design floating head directly across from foam…