The genesis of this post is from a LinkedIn post: Common wisdom in manufacturing often holds that replicating the systems of successful giants, like Toyota, is the path to profitability. Yet, as the original post points out, many organizations meticulously follow the playbook—implementing 5S, 5-Why, and visual management—only to fail in the market.  We have […]

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 […]

Transparency in Testing and Why It Matters Before going into this post, I want to apologize to Rachel Evans for not being able to attend the Automotive Testing Expo in Novi, Michigan. This goes beyond her and to all who had planned to meet me and chat about this vital topic area of product testing.  There was […]

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 […]

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 […]

Jon M Quigley The Benefits of Swim Lane Process Flows for Engineering, Manufacturing, and Procurement Swim lane process flow benefits in product development.  Product development is a complex journey that involves multiple teams and departments, including engineering, manufacturing, and procurement.  This requires coordination across the board, not optimization of a single department, but balancing the […]

By Jon M Quigley Pareto charts for quality improvement are a powerful tool for focusing limited resources on the problems that matter most. Rather than treating all defects or process variations equally, Pareto analysis highlights the small number of issues that cause the majority of quality disruptions. This structured approach enables manufacturers to identify patterns […]

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, […]

By Jon M Quigley This post is to pile on to a post by Robert Fey on LinkedIn. Below is a brief brainstorm of issues that can arise in product development and testing, resulting in poor outcomes.  Your thoughts are welcome. Here is a list of common failures in the context of software verification work […]

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 […]