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Every failure adds a signature

Every failure adds a signature

This article is part of the How Do YOU CM2? blog series in collaboration with the Institute for Process Excellence (IpX). Although I receive compensation for writing this series, I stand behind its content. I will continue to create and publish high-quality articles that I can fully endorse. Enjoy this new series, and please share your thoughts!  In my article on Conway’s Law, I describe the change process as the place where the right… Read More »Every failure adds a signature

The Bin Test You Outsourced

The Bin Test You Outsourced

This article discusses the importance of ongoing verification in the First Article Inspection (FAI) and Production Part Approval Process (PPAP) in aerospace and automotive industries. Both processes ensure that changes in production do not affect part quality, emphasizing the need for continuous oversight and accountability beyond initial approvals.

Flight-Proven

Flight-Proven

The failure of Ariane 5’s maiden flight stemmed from an inertial reference system designed for Ariane 4, which was inadequate for its faster velocity. This incident highlights the dangers of assuming prior success in similar systems without reassessing their applicability to new contexts. Verification methods must include clear scope definitions to prevent such oversights.

Jefferson Witnessed Both Demonstrations

Jefferson Witnessed Both Demonstrations

Thomas Jefferson observed two key demonstrations of interchangeability: Honoré Blanc’s honest display in 1785, where random parts fit perfectly, and Eli Whitney’s staged 1801 demonstration, which misled observers and led to delays. The outcomes reflect the importance of who selects components during tests, emphasizing the need for impartiality in acceptance evaluations.

The Promise Lives in People’s Heads

The text discusses the critical gap in knowledge retention within manufacturing, particularly as veteran engineers near retirement. It emphasizes that interchangeability assessments rely on historical context often lost when experienced employees leave. Solutions, like capturing decision-making context, are proposed to build “product memory” and ensure continuity for future engineers.

One Part, Five Numbers

The article highlights the issue of parts with duplicate numbers obscuring interchangeable parts. It emphasizes the hidden costs of managing duplicates, which can lead to inefficiencies and lost savings. By implementing better identification schemes, organizations can reclaim the value of interchangeable items, potentially saving millions annually. Understanding and managing these duplicates is essential for operational efficiency.

The Regulator Is About to Ask for the Receipts

Starting February 18, 2027, EU regulations will require traceability for every EV battery through the Digital Product Passport, mandating records of production details. Effective configuration management is essential for compliance to avoid false declarations. Organizations must treat this regulation as a critical data discipline rather than merely a sustainability exercise.

Why Unmanaged Engineering Notes are a Legal Nightmare!

Why Unmanaged Engineering Notes Are a Legal Nightmare!

This article discusses the importance of structured reasoning capture in product design, emphasizing that while documenting decisions can expose liability in court, disorganized records pose even greater risks. Effective governance of documented reasoning creates a defensible narrative, contrasting with unregulated documentation, which can lead to catastrophic legal outcomes, as seen in high-profile cases.

Product Memory and the Security Paradox

Product Memory and the Security Paradox

This article discusses the risks associated with Product Memory in design processes, emphasizing the importance of securing not just product data but also the underlying rationale behind design decisions. It warns that careless handling of this information can create significant competitive risks and calls for stringent access controls and classification to protect sensitive reasoning.

The reasoning most worth capturing is the reasoning your experts can't articulate.

The reasoning most worth capturing is the reasoning your experts can’t articulate. 

The article highlights the challenges of capturing tacit knowledge in engineering design, emphasizing that valuable insights often exist informally within experienced professionals. It advocates for recording reasoning during decision-making processes and acknowledges the importance of mentoring, suggesting a balanced approach between documentation and recognizing human expertise in knowledge management.