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 […]
When the Margin Is Unknown, Control Becomes Reaction Not everything can be turned into a process. This is especially true in early product development, where learning, discovery, and iteration dominate. However, when ambiguity persists beyond its appropriate stage—especially around dimensions, tolerances, and margins—organizations unintentionally transfer risk downstream. The image illustrates a simple truth: when the […]
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 […]
Introduction Every organization faces unexpected issues—but how you respond defines your success. When deviations from standard procedures are mismanaged or ignored, the result can be catastrophic: product recalls, regulatory fines, and irreparable brand damage. A deviation in manufacturing refers to a temporary or unplanned departure from approved procedures, specifications, or standards during the production process. […]
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 […]
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, […]
Configuration Management Vehicle Platforms – Practices for Multi-Project Success In the dynamic world of vehicle platform development, configuration management is more crucial than ever. As manufacturers innovate, multiple projects often require changes across various vehicle systems built on the same platform. Ensuring seamless, high-quality integration demands robust strategies―especially branching and merging―to keep development efficient and […]