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 […]

What is a Project Escalation Plan in Product Development? A project escalation plan for product development is a structured approach to identify, address, and resolve issues that threaten a project’s goals, timelines, or budget. These plans ensure problems are managed before they impact overall product success. To illustrate, and this is not my project, I was a […]

Automotive Testing Best Practices: SIL, HIL, and Why a Single Approach Falls Short by Jon M Quigley As someone deeply engaged in automotive product development and testing, I believe that robust strategies using both software-in-the-loop (SIL) and hardware-in-the-loop (HIL) are essential. Drawing on the insights and frameworks of Jon M. Quigley, I want to explore […]

Introduction Success in today’s workplace depends on the intricate balance of team and individual performance. Organizations striving for innovation recognize the importance of empowering individuals while fostering effective teamwork. Drawing on the insights of legendary quality management thinker W. Edwards Deming, this post examines motivational factors, the impact of self-interest, and the most effective actions to […]