Operations

A sound that’s slightly off before a bearing fails. A smell that shows up before a chemical reaction runs hot. A texture that feels wrong before any instrument confirms it. Frontline workers pick up on signals like these constantly and, most of the time, nothing in the plant is built to capture…

At a typical manufacturer, the cost of poor quality runs to 15–20% of sales. Shellye Archambeau, a Quality Digest contributor, once put a face on that number: A $250 million company added up its repair, rework, scrap, warranty, and write-off costs, and found they equaled 20% of sales. That’s one…

A foundry can produce an impressive inspection package and still leave its customer with an unanswered question: Which records actually supported the decision to ship this part?

An alloy chemistry report might identify a melt. An X-ray image could show one internal area. A…

With the publication of the new VDA AIAG SPC Manual in July 2026, one of the most significant changes to statistical process control (SPC) in decades has been introduced. While much attention has been given to the new process capability indices, an equally important change is the introduction of…

There’s a number that stopped me in my tracks recently. U.S. manufacturers spent about $32 billion training and upskilling their people—a 22% jump from 2019—and the average worker now logs close to five more training hours a year than they did back then, climbing from 42.9 hours to 47.6 (…

Engineers often use vision-language models to produce new designs, such as for airplane or automobile components. To simulate how those components will perform in realistic situations, they’ll use tried-and-true computer-aided design (CAD) software to generate 3D models of those designs that…