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 […]
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 […]
Factory Acceptance Test (FAT) and Site Acceptance Testing (SAT) Overview In product development, acceptance testing is a cornerstone of predictable, high-quality system deployment. As one of the authors of Configuration Management Theory and Practice, Testing of Complex and Embedded Systems, and multiple industry articles, I often emphasize that product and system verification must validate performance across both controlled […]
Openness Builds Stronger Cultures In the past few weeks, I’ve been reflecting on a pattern that appears across high-performing, logic-driven organizations: brilliant teams slowly losing momentum because the fight to be proper overshadows the desire to understand. Then I saw this LinkedIn article, which is the genesis of this article. I have worked on teams […]
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 […]
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 […]
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 […]
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 […]