Why Test Failures Occur in Software Testing In software development and system engineering, test failures are often interpreted as evidence that the product contains defects. However, experienced engineers know that test failures can originate from multiple sources across the development lifecycle, not just the code itself.  This post originated from a read of a LinkedIn […]

Risk Sensitivity Balance in Product Development and Manufacturing: Calculated Risks in a Technology-Driven World In today’s hypercompetitive environment, product development and manufacturing risk management have become strategic differentiators. Organizations that master risk sensitivity balance outperform those that either recklessly gamble or cautiously stall innovation.  I have spoken and taught on risk management. Whenever risk comes […]

New Part Number vs Revision Level in Product Management One of the most debated topics in product management and configuration management is the decision between New Part Number and Revision Level. When should a design change require a brand-new part number?When is a revision level update sufficient? The answer affects traceability, supply chain management, quality control, […]

The Business Cost of Inadequate Testing and Verification Inadequate Testing Priorities: The Hidden Business Risk in Product Development In product development, testing and verification are often praised in principle but underfunded in practice. Organizations regularly declare quality as a core value, yet budget allocations and schedule pressures reveal a different reality.  I am grateful to […]

Quality Improvement in Product Development: The Horse Isn’t Even Near the Water Before we go any further with this blog post, I need to note that this stems from recent consulting work that demonstrated the principle.  But that would not have been enough even though these thoughts were rolling through my head.  The catalyst was […]

Why Software-Defined Vehicles Demand Stronger Verification and Validation Software-defined vehicles (SDVs) are reshaping automotive engineering. Vehicle behavior is no longer fixed at production; it evolves through over-the-air (OTA) updates, software feature toggles, and AI-enabled decision logic. This shift dramatically raises the stakes for SDV verification.  Personally, I think treating a vehicle like IT equipment may […]

PFMEA Control Gap: Control Plan Tools That Fail During Transition The PFMEA (Process Failure Mode and Effects Analysis) control gap is one of the most common root causes of quality failures in manufacturing. It occurs when the Process Failure Mode and Effects Analysis (PFMEA) indicates that risks are controlled, but actual shop-floor execution indicates otherwise.  […]

The Iterative Development Process in Modern Product Development The iterative development process is not a single activity or phase—it is a system of interconnected disciplines working together throughout the product lifecycle. The attached graphic illustrates this system as a set of interlocking gears, each representing a critical capability required to move from concept to successful […]

Deterministic vs Probabilistic: Definitions that Matter in Engineering In engineering, deterministic vs. probabilistic refers to how we model cause-and-effect relationships and uncertainty.  The difference between the two requires concepts that are important and should drive how we behave.  A deterministic view assumes that the same inputs will always produce the same output; given the system […]

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 […]