Leak Testing: Choose the Method From the Function, Not the Habit
Most leak limits trace back to a drawing, a customer or habit — never to function. Here is how to…
Six Sigma & Data
150 articles
Manufacturing Data Architecture for Quality: Getting to One Version of Truth
Why two dashboards disagree in the same plant, and the structural fixes: context records, time alignment, unit-centric joins, and the…
The Quality Engineer Employed as an Administrator: Reclaiming the Role
Most quality engineers spend their week servicing documents instead of processes. Here is how the drift happens, what it costs,…
Solder Joint Acceptance: Reading IPC Classes Without Over-Rejecting
Most false rejects at the inspection bench come from applying Class 3 habits to Class 2 product. Here is how…
Coating Thickness Conformity Is Decided by Measurement Location
Most plating thickness disputes are not about chemistry or process capability. They are about which region of the part the…
Pilot Parts That Flatter You: How Prototype Processes Overstate Production Capability
Prototype parts answer questions of design and fit, not of process capability. Here is why pilot data flatters production, and…
Burn-In Economics: Screening Cost Versus Escaped Infant Mortality
How to size, monitor and eventually retire a burn-in screen using failure physics, fallout signatures and life-consumption arithmetic rather than…
Survival Analysis for Warranty Data: Getting Censored Units Right
Most units in a warranty fleet have not failed yet. Here is how to use censored data, Kaplan-Meier curves and…
MTBF Is a Rate, Not a Lifespan: How to Use It Without Being Misled
Why the most quoted reliability figure describes almost nothing you care about, and what to demand instead: Weibull shape parameters,…
Utility Variation: The Process Input Your Documentation Never Lists
Compressed air, electrical power and water are treated as constants in process definitions. They vary, and the variation produces defects…