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The Engineering department does not design for manufacturing. It seems that efficiency and costs are not considered in the design phase.
2) By buying lumber cut to length he would have cut production time, waste, labor and costs related with tooling. Less space would have been required. It is also likely that the quality of the material would have been better as a lumber yard uses better tools than a skill saw.
a) Joe applies a rigid method without thinking ahead and works with concepts that do not apply to what he is doing because he does not know otherwise. Bulk is always cheaper does not work in his case...
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