Quality during Design

When pursuing aggressive benchmarks, engineers must employ portfolio thinking, running multiple design projects simultaneously. But choosing winners requires a decisive way to eliminate projects that are not feasible to continue innovating, often referred to as a "project killer". In this episode, we analyze Tesla's battery development as a case study. We delve into their use of five clear-cut constraint categories that define failure conditions upfront: the Economic filter, Performance...

We turn late-stage design surprises into a strategic plan by assigning explicit confidence levels, stacking evidence, and using the three-dial model of time, cost, and confidence boost. We show how to work backward from a system test to cheaper steps that drive faster, clearer decisions. • applying the three dials of time, cost, confidence • sequencing with the work-backwards strategy • avoiding overtesting, undertesting, wrong testing • turning confidence into a team communication tool • pr...

Late-stage design just hit a snag—now comes the moment that separates guesswork from great engineering. We walk through a clear, repeatable method to investigate unexpected failures and make high-impact decisions with confidence. Instead of hunting for a perfect test, we set a confidence target and stack multiple forms of imperfect evidence until we close the gap. If you’re navigating late-stage product development and want a calm, methodical way to move from 40% to 90% confidence, this fram...

We break down why risk analyses often become checkbox theater and replace them with a simple, practical impact vs likelihood matrix that guides action. From quick wins to high-stakes unknowns, we show how to calibrate effort, buy the right learning, and move with confidence. Join the Substack for monthly guides, templates, and QA where I help you apply these to your specific projects. Are your teams struggling with poor communication and rushed timelines? Is your product vision clouded...

If you reach for the nearest “risk” template, it might cause more problems. There are two very different jobs we ask risk tools to do. In this episode, we talk about how to pick the one that actually moves your project forward. identification tools for unknown unknowns (like FMEA and preliminary hazard analysis) that systematically surface risks to users, systems, and environmentsdecision tools for known unknowns that clarify impact, likelihood, and uncertainty so teams can choose a path with...