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 […]

Welcome to the Project Management Failure Olympics Ah, project management failure, the unsung art form of modern enterprise! Anyone can deliver a project successfully—boring. But to craft a truly magnificent fiasco? That takes vision, overconfidence, and a Gantt chart that looks like spaghetti. The goal isn’t to finish the project. No, it’s to appear incredibly busy while chaos spreads […]

BOM Data Integrity in a “Post‑BOM” World (and Why I Disagree)   Reading “2026 – The year we have to unlearn BOMs!” immediately brought back decades of scars from broken configurations, field failures, and costly recalls rooted in poor BOM data integrity. The thesis that classic assemblies and traditional BOM thinking have become obsolete misses […]

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 […]

Why You Should Stop Calling It an Engineering Change and Start Saying Enterprise Change When I hear the phrase Engineering Change, alarm bells go off in my head. Not because I have something against engineers—I am one—but because the term limits the conversation and the scope of our thinking. In my decades of experience, I’ve […]

Automotive Testing Best Practices: SIL, HIL, and Why a Single Approach Falls Short by Jon M Quigley As someone deeply engaged in automotive product development and testing, I believe that robust strategies using both software-in-the-loop (SIL) and hardware-in-the-loop (HIL) are essential. Drawing on the insights and frameworks of Jon M. Quigley, I want to explore […]

The Need for Transparency in Testing In the high-stakes world of automotive product development, demands to deliver vehicles on schedule often collide with the critical necessity for transparency in testing results. When timelines tighten and executive pressure mounts, the temptation to “fast-track” projects at the expense of rigorous verification grows. Yet, ensuring transparency in testing […]

Prototype Parts vs Production Parts: Understanding Key Differences and the Path to Production Introduction The journey from an initial concept to a finished product involves several crucial stages, including prototyping and production. For both engineers and procurement teams, it’s vital to understand the differences between prototype parts, their uses, and the technical, regulatory, and supply chain […]