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 […]
The ROI Trap in Equipment Maintenance Decisions It is cool when I hear engineers early in their career chat with me about their engineering, both design and manufacturing. about, well, I want to say face-palm moments. One such example is when executives often ask for ROI on equipment maintenance numbers, even though the line has long […]
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 […]
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, […]
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. […]
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 […]
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 […]
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 […]
Introduction In today’s competitive market, understanding the gears of product development is crucial for delivering successful products. Each element—like requirements elicitation, configuration management, and risk management—acts as a gear in a well-oiled machine. When these gears work in harmony, teams can accelerate innovation, minimize risk, and maximize the value of their products. This is not […]
Why Purchasing Matters in Project Management Purchasing is a cornerstone of successful project management, directly impacting cost, quality, and schedule. Purchasing and supplier selection figure prominently in product development and project management, emphasizing that effective purchasing is not just about buying goods or services—it’s about strategic supplier selection, risk management, and aligning procurement with project […]