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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

Can Configuration Management Defeat Conway's Law?

Can Configuration Management Beat Conway’s Law?

This article discusses the challenges organizations face due to siloed structures, as highlighted by Conway’s Law. It emphasizes the importance of a change process in fostering cross-functional collaboration, enabling better communication between departments. The author advocates for configuration management as a means to effectively manage change and break down silos, ultimately enhancing organizational efficiency.

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.

Would Your Parts Still Pass the Bin Test?

Would Your Parts Still Pass the Bin Test?

On August 30, 1785, Thomas Jefferson observed a demonstration by Honore Blanc, showing the interchangeability of musket lock parts. This highlighted the importance of validation over mere declarations. The article discusses modern challenges in proving interchangeability, emphasizing a structured process to ensure claims are supported by evidence and not just assumptions.

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.

Interchangeable Does Not Mean Identical

The debate around the “Part Proxy” concept, introduced by Prof. Dr. Jörg W. Fischer, highlights challenges in managing interchangeable parts across different plants in manufacturing. It emphasizes the need for proper identification and interchangeability criteria, advocating for distinct part numbers when constructions differ, while maintaining a system for equivalent items to ensure clarity in manufacturing processes and documentation.