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 […]
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 […]
The Fantasy of No Regrets Thinking “No regrets.” It’s tattooed on forearms, stamped under vacation photos, and whispered like a life hack. But no regrets thinking assumes something profoundly unrealistic: that you had perfect information, flawless judgment, and a crystal ball. You didn’t. Adults make decisions under uncertainty. Children assume outcomes are obvious. That’s the […]
Commercial Vehicle Dictionary for Engineers, Fleet Managers, and Transportation Professionals Clear communication is essential in the commercial transportation industry. Engineers, fleet managers, manufacturers, and regulators rely on precise terminology to design vehicles, maintain fleets, meet regulations, and reduce risk. Yet, commercial vehicle terminology is often inconsistent across organizations and regions. That inconsistency leads to misunderstandings, […]
A Product Is Both Good and Bad—Until Tested Not everything can be turned into a process. This is especially true early in product development, where ideas evolve faster than data. But there is a dangerous phase where uncertainty masquerades as progress. Like Schrödinger’s famous thought experiment, an untested product exists in a paradoxical state: it […]
Problems Are Symptoms of Unmanaged Risk by Jon M Quigley This post is in response to an article on LinkedIn from Habib ur Rehman on blaming operator mistake as the root cause, and operator training as corrective action. This article is very timely, as I have been involved in consulting work where this situation was […]
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: 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 […]
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. […]