Why Software-Defined Vehicles Demand Stronger Verification and Validation Software-defined vehicles (SDVs) are reshaping automotive engineering. Vehicle behavior is no longer fixed at production; it evolves through over-the-air (OTA) updates, software feature toggles, and AI-enabled decision logic. This shift dramatically raises the stakes for SDV verification.  Personally, I think treating a vehicle like IT equipment may […]

PFMEA Control Gap: Control Plan Tools That Fail During Transition The PFMEA (Process Failure Mode and Effects Analysis) control gap is one of the most common root causes of quality failures in manufacturing. It occurs when the Process Failure Mode and Effects Analysis (PFMEA) indicates that risks are controlled, but actual shop-floor execution indicates otherwise.  […]

Deterministic vs Probabilistic: Definitions that Matter in Engineering In engineering, deterministic vs. probabilistic refers to how we model cause-and-effect relationships and uncertainty.  The difference between the two requires concepts that are important and should drive how we behave.  A deterministic view assumes that the same inputs will always produce the same output; given the system […]

What PPAP Is Trying To Achieve (And Often Does) At its best, PPAP in manufacturing is a structured way to prove that a supplier’s process can repeatedly produce parts that meet all customer and regulatory requirements. The AIAG PPAP intent aligns with Ioan Feloniuk’s framing: demonstrate that design intent, process capability, and evidence are in place […]

APQP Testing Limitations in Automotive and Manufacturing Quality Advanced Product Quality Planning promises robust launches, but APQP testing limitations often emerge when teams equate “meets spec” with “fit for use.” APQP testing limitations become most evident when products pass all defined tests yet still fail in customer applications, field use, or long-term durability. The root cause […]

What Is IATF 16949 Standard? The IATF 16949 standard is the global benchmark for automotive quality management systems, built on ISO 9001 and tailored to the automotive supply chain. It defines how organizations design, develop, produce, install, and service automotive products while continually improving, preventing defects, and reducing variation and waste.  Standards often get a […]

When the Schedule Is “Managed” but Still Sinking Not everything can be turned into a process—especially in product development, where discovery and uncertainty are unavoidable. But there is a dangerous gap between acknowledging uncertainty and pretending it is under control. The image illustrates a familiar scenario: a project manager confidently “monitoring and controlling” while the […]

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 […]

The PFMEA–Control Plan Connection in Manufacturing A robust PFMEA connected to a control plan strategy is essential when launching a new manufacturing line or improving an existing one. The Process Failure Mode and Effects Analysis (PFMEA) identifies where and how a process might fail, while the control plan documents how those risks will be monitored, […]

Manufacturing Repeatability and the Importance of Repeatable Processes Manufacturing organizations striving for predictable, high-quality output often discover that manufacturing repeatability is not achieved by accident—it is engineered through disciplined, repeatable processes. In competitive markets, manufacturers cannot rely on tribal knowledge or inconsistent practices; they must establish process stability that consistently converts raw materials into reliable […]