PPAP Risk Management: Why Most PPAP Approvals Still Fail at Production Launch I recently reviewed a visual guide titled “How to Create PPAP – Complete Practical Master Guide.“ Like many PPAP references circulating online, it does an excellent job explaining the documentation requirements, submission levels, and elements of the Production Part Approval Process. What it […]

Executive Decisions and Product Launch Failure Most executives do not wake up in the morning intending to launch a defective product. They are not trying to damage customer trust. They are not attempting to trigger recalls, incur warranty costs, or cause reputational damage. Most are attempting to balance delivery schedules, investor expectations, internal politics, manufacturing […]

Product Development Writing — Engineering Beyond Engineering I never intended to become a writer. I intended to become a product development professional. Like many engineers, I initially believed technical competence and creativity would largely determine success. Certainly, strong engineering capability matters. But over time, reality exposes a far more complicated truth: Products rarely fail solely […]

The reflex response after a defect escape is often predictable: add more inspectors. More containment. More gate reviews. More signoffs. More checklists. The organization feels pressure to “do something,” and inspection fallout becomes the preferred reaction because it is visible, immediate, and politically safer than confronting systemic process weakness. The problem is that inspection fallout […]

Product Launch Delays Continue to Impact Automotive and Technology Programs A recent Gartner study noted that nearly half of product launches experience delays of at least one month. That statistic should surprise nobody working in modern vehicle development, software-defined systems, or complex manufacturing programs. The causes of Product Launch Delays are often deeper than scheduling […]

How to Use AI in Business Processes for Faster Quoting, Smarter Design, and Improved Manufacturing Quality Artificial intelligence is no longer experimental—it is becoming essential for companies looking to improve speed, accuracy, and decision-making. The real opportunity lies in applying AI business processes across the value chain, particularly in quoting, design exploration, material substitution, and […]

Why Most Testing Strategies Fail: The Real Problem Isn’t Testing This post is borne out of a LinkedIn post.  If you’re responsible for testing, here’s a simple question: 👉 Do you actually know what’s going on? Not what’s reported.Not what’s assumed.What’s really happening? Because in most organizations, what looks like a testing strategy failure isn’t […]

Introduction – Delays Are a Symptom, Not the Problem “Engineering needs three more weeks.” This post was prompted by a LinkedIn post Prevent Delays with CM2.  This statement has become normalized across industries, yet it signals something deeper than scheduling inefficiency. Configuration Management Delays are not caused by lack of effort, poor planning, or even […]

The global conversation about why projects fail often centers on methodology, certification, or process discipline. Yet despite decades of frameworks, certifications, and governance models, project failure rates still hover between 70% and 88% across industries.  This post is in response to a LinkedIn post from Michael Kaplan. The problem is not always a lack of project […]

Modern products are rarely single, fixed configurations. Instead, they exist as families of variants designed to meet different customer needs, regulatory requirements, and operational environments. Managing this complexity requires a disciplined approach to product structure, configuration management, and verification. One of the most important concepts supporting this effort is the 150% eBOM.  That leads to […]