Executive Decisions and Product Launch Failure Most executives do not wake up in the morning intending to launch a defective product. They are not trying to damage customer trust. They are not attempting to trigger recalls, incur warranty costs, or cause reputational damage. Most are attempting to balance delivery schedules, investor expectations, internal politics, manufacturing […]
Product Development Writing — Engineering Beyond Engineering I never intended to become a writer. I intended to become a product development professional. Like many engineers, I initially believed technical competence and creativity would largely determine success. Certainly, strong engineering capability matters. But over time, reality exposes a far more complicated truth: Products rarely fail solely […]
Relaxation in Moderation and Sustainable Success Relaxation is important. Recovery matters. Rest is necessary. But “relaxation in moderation” is an idea that deserves more scrutiny than most people give it. In modern culture, relaxation is often marketed as a permanent or desired end state: avoid stress, minimize discomfort, seek convenience, optimize ease, remove friction. Yet […]
The ROI Trap in Equipment Maintenance Decisions It is cool when I hear engineers early in their career chat with me about their engineering, both design and manufacturing. about, well, I want to say face-palm moments. One such example is when executives often ask for ROI on equipment maintenance numbers, even though the line has long […]
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, […]