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 […]

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 […]

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 — […]

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 […]

Understanding Lean Process Limits Lean principles have transformed how we design and manufacture products. By emphasizing waste reduction, continuous improvement, and customer value, lean thinking drives productivity and focus. Yet, even discipline can turn dangerous when taken to extremes—revealing what we might call the limits of lean processes.  Everything has limits, and exceeding those limits […]

Work Instruction Updates: Capturing Continuous Improvement and Tribal Knowledge By Jon M Quigley Why Work Instruction Updates Matter Work instruction updates are more than administrative chores; they are potent tools for continuous improvement and the preservation of tribal knowledge. As organizations adapt to changing customer needs, technological shifts, and workforce turnover, the need to capture, […]

Introduction Manufacturing organizations striving for excellence often rely on two powerful forces: manufacturing continuous improvement and robust documentation. Yet, connecting what truly happens on the shop floor with what gets recorded can be far more challenging than it seems. This gap between practice and documentation often leads to inefficiencies, inconsistent training, and the risk of losing […]

Product Quality in Product Development Project Management Introduction In today’s competitive market, product quality is not just a desirable attribute—it’s a fundamental requirement for successful product development and project management. Integrating product quality into every project lifecycle ensures that the final product meets customer expectations, regulatory standards, and business goals.  The quality of the product […]

  My thoughts on this LinkedIn post Judging a process by its outcomes in organizations, teams, and even personal projects is common. When things go awry, the immediate instinct is often to blame the process itself. However, this overlooks a crucial distinction: a well-designed process can still yield poor results if executed improperly. Consider a […]

Understanding Metrics Masking Failure in Automotive Projects In the automotive industry, project metrics are essential for tracking progress, ensuring safety, and delivering quality products. However, as Jon M. Quigley emphasizes, metrics alone do not guarantee project success, especially when they confirm what stakeholders already want to believe rather than reveal the actual state of a […]