The genesis of this post is from a LinkedIn post: Common wisdom in manufacturing often holds that replicating the systems of successful giants, like Toyota, is the path to profitability. Yet, as the original post points out, many organizations meticulously follow the playbook—implementing 5S, 5-Why, and visual management—only to fail in the market. We have […]
Introduction: Feedback Loop Beginnings The genesis of this article is a text from a longtime friend, Jason Newton, from my UNCC days. He is a musician, not a mimic like I consider myself, and an engineer of high caliber. He sent me a shirt with a saying, “I only give Negative Feedback,” along with an Op-Amp […]
Introduction Every organization faces unexpected issues—but how you respond defines your success. When deviations from standard procedures are mismanaged or ignored, the result can be catastrophic: product recalls, regulatory fines, and irreparable brand damage. A deviation in manufacturing refers to a temporary or unplanned departure from approved procedures, specifications, or standards during the production process. […]
The PPAP Process Flow The PPAP process flow (Production Part Approval Process) is a cornerstone of modern manufacturing quality systems, particularly in automotive and industrial sectors. It ensures that every part delivered meets customer expectations by validating that the production process can consistently produce conforming components. PPAP is part of the Advanced Product Quality Planning […]
Understanding Lean Process Limits Lean principles have transformed how we design and manufacture products. By emphasizing waste reduction, continuous improvement, and customer value, lean thinking drives productivity and focus. Yet, even discipline can turn dangerous when taken to extremes—revealing what we might call the limits of lean processes. Everything has limits, and exceeding those limits […]
What is 2D Barcode Traceability? 2D barcode (also known as QR Code or Data Matrix) traceability drives modern manufacturing efficiency by linking every product to its digital records, including build instructions and test data. Unlike traditional labels, 2D barcodes such as Data Matrix or QR codes can encode a unique job ID, serial number, or […]
Jon M Quigley Change is inevitable, including in the manufacturing industry. Whether it’s for cost reduction, supplier updates, design improvements, or compliance requirements, moving from one version of components on a manufacturing line to another is a critical process that must be carefully controlled to protect product quality and continuity. The process begins with the Engineering Change […]
Work Instruction Updates: Capturing Continuous Improvement and Tribal Knowledge By Jon M Quigley Why Work Instruction Updates Matter Work instruction updates are more than administrative chores; they are potent tools for continuous improvement and the preservation of tribal knowledge. As organizations adapt to changing customer needs, technological shifts, and workforce turnover, the need to capture, […]
Configuration Management Vehicle Platforms – Practices for Multi-Project Success In the dynamic world of vehicle platform development, configuration management is more crucial than ever. As manufacturers innovate, multiple projects often require changes across various vehicle systems built on the same platform. Ensuring seamless, high-quality integration demands robust strategies―especially branching and merging―to keep development efficient and […]
Why You Should Stop Calling It an Engineering Change and Start Saying Enterprise Change When I hear the phrase Engineering Change, alarm bells go off in my head. Not because I have something against engineers—I am one—but because the term limits the conversation and the scope of our thinking. In my decades of experience, I’ve […]