BOM Data Integrity in a “Post‑BOM” World (and Why I Disagree)   Reading “2026 – The year we have to unlearn BOMs!” immediately brought back decades of scars from broken configurations, field failures, and costly recalls rooted in poor BOM data integrity. The thesis that classic assemblies and traditional BOM thinking have become obsolete misses […]

Problems Are Symptoms of Unmanaged Risk  by Jon M Quigley This post is in response to an article on LinkedIn from Habib ur Rehman on blaming operator mistake as the root cause, and operator training as corrective action. This article is very timely, as I have been involved in consulting work where this situation was […]

Factory Acceptance Test (FAT) and Site Acceptance Testing (SAT) Overview In product development, acceptance testing is a cornerstone of predictable, high-quality system deployment.  As one of the authors of Configuration Management Theory and Practice, Testing of Complex and Embedded Systems, and multiple industry articles, I often emphasize that product and system verification must validate performance across both controlled […]

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 […]

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, […]

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 […]

The Need for Transparency in Testing In the high-stakes world of automotive product development, demands to deliver vehicles on schedule often collide with the critical necessity for transparency in testing results. When timelines tighten and executive pressure mounts, the temptation to “fast-track” projects at the expense of rigorous verification grows. Yet, ensuring transparency in testing […]

Configuration management (CM) and product testing and verification are inextricably linked processes crucial for successful product development and production. Without effective configuration management, performing effective testing becomes difficult. CM provides the foundation for efficient, reliable, and insightful testing activities in today’s complex and constantly evolving systems across automotive, aerospace, defense, and software development industries.  This […]

What is Software Download Over the Air (DOTA)? Jon M Quigley Software download over the air (OTA) refers to the wireless delivery of software updates, patches, or new features directly to devices without the need for physical connections or manual intervention. This technology is widely used in smartphones, IoT devices, vehicles, and enterprise systems to […]