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 […]
Why SDVs Demand Stronger Verification and Validation The shift to software‑defined vehicles (SDVs) is transforming automotive engineering—and multiplying its risks. As ECUs consolidate into centralized compute platforms and features increasingly rely on AI, machine learning, and over‑the‑air (OTA) updates, safety, cybersecurity, and reliability take center stage. This complexity makes verification and validation (V&V) more critical than ever. Regulators are tightening expectations […]
The Growing Myth of OTA Quick Fixes The automotive industry loves the promise of OTA software updates. The idea that misbehavior in the field can be “fixed remotely” has become part of both product strategy and marketing. Industry voices often proclaim, “If something goes wrong, we’ll just push an update.” Yet, rising software-related recalls and increasing regulatory scrutiny tell a […]
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 […]
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 […]
When Testing Competes with the Calendar Not everything can be turned into a process—especially early in product development, where learning is still underway. However, one decision consistently creates downstream damage: allowing testing to compete directly against launch dates. The image captures a familiar and dangerous scenario—standing still on the tracks while “time to ship” accelerates […]
By: Jon M Quigley When Process Helps—and When It Can’t We are a big fan of Aircraft Disasters on the Smithsonian Channel (at least that is where we watch it). This often appears in our written materials, including the occasional blog post. This post origins from the season 4 episode 7, “Catastrophe at O’Hare” as well […]
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 […]