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Not really a joke. The threshold is much lower than you might think. It’s much cheaper to simply build and try out even fairly simple things than to model them accurately enough in expensive software to try out.
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It's also perhaps related that hardware development / production hasn't really got much faster over time. The Model T factory was built/tooled-up in 3 years and each car took 90 minutes of total assembly time. 100 years later, a new F-150 takes 5 years, 180 minutes.
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You'd think with all the robotics, etc. that we'd get big speed-ups. Of course the part count / complexity of the F-150 is probably 5-10x the Model T, but still it's kind crazy how glacial 100 years of progress in hardware tools has been.
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While I don't have much to say for unions improving production, but I actually don't think it's the major factor. Tesla for instance wasn't union and people at all levels I met were trying hard without union-esque BS.
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