Know Your Manufacturing Process Baseline Before Improving Before diving into advanced line upgrades or expensive automation, the first step is to understand the manufacturing process baseline. What do you change if you do not know what needs to be changed and why? This involves collecting detailed data on how a manufacturing line currently performs — […]
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 […]
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 […]
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, […]
Introduction Manufacturing organizations striving for excellence often rely on two powerful forces: manufacturing continuous improvement and robust documentation. Yet, connecting what truly happens on the shop floor with what gets recorded can be far more challenging than it seems. This gap between practice and documentation often leads to inefficiencies, inconsistent training, and the risk of losing […]
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 […]
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 […]
Introduction In today’s competitive market, understanding the gears of product development is crucial for delivering successful products. Each element—like requirements elicitation, configuration management, and risk management—acts as a gear in a well-oiled machine. When these gears work in harmony, teams can accelerate innovation, minimize risk, and maximize the value of their products. This is not […]