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 […]
Know Your Manufacturing Process Baseline Before Improving Before diving into advanced line upgrades or expensive automation, the first step is to understand the manufacturing process baseline. What do you change if you do not know what needs to be changed and why? This involves collecting detailed data on how a manufacturing line currently performs — […]
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 […]
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 […]
What is 2D Barcode Traceability? 2D barcode (also known as QR Code or Data Matrix) traceability drives modern manufacturing efficiency by linking every product to its digital records, including build instructions and test data. Unlike traditional labels, 2D barcodes such as Data Matrix or QR codes can encode a unique job ID, serial number, or […]
Jon M Quigley The Benefits of Swim Lane Process Flows for Engineering, Manufacturing, and Procurement Swim lane process flow benefits in product development. Product development is a complex journey that involves multiple teams and departments, including engineering, manufacturing, and procurement. This requires coordination across the board, not optimization of a single department, but balancing the […]