@Ann- LOL, shame on you for not switching hats from Engineering to Sales/Mktg ! The tape is a major breakthrough because it does not need to have sides identified. Both sides of the tape have equal conductivity. This saves a lot of time, labor, and chance for error on the production floor. :)
Sounds like something that worked fine in the lab but was never tested under actual production conditions, e.g. winding onto a large roll. Plastic stretches; metal films don't.
It's surprising how little stretching is required to make metal coatings break--I had a fair amount of frustrating experience making thermal imagers out of metallized PVDF film before I switched to carbon-loaded ink. That stuff was stretchy enough to take a hard crease, and conductive enough for the job. (There's a war story at http://electrooptical.net/www/footprints/fpwaropn.pdf, and a bit more discussion at http://electrooptical.net#footprints.)
It sounds to me like quality is reporting to the wrong person. From the top down, if quality is reporting to operations they will be forced to push it through rather than slow down or stop production making them do it right. The goal of quality has to be quality and quality only. And they should report through a different chain of command all the way to the top. That way the big guy can tell quality to focus on quality and operations to focus on making good products.
Funny how often the products we put out are dictated by the system that we choose to function in and the directions we are given from the top down.
I'm guessing there is no quality control within the manufacturing process. And for something like this, which could be used as a safety device, I would think the manufacturer would have to have some on-line testing to prove the product is capable of delivering on the specifications.
I find this story interesting as well as your reply. It sounds to me like the design system was broken. In some companies the lines and definitions on what people are supposed to deliver are so blurry that things get overlooked. Never quite so big a thing as this. but still, how often does quality put on their engineering hat and start to solve the engineering problem rather than validating the design. How often do engineers start talking to vendors because, it's just easier and then I don't have to deal with purchasing.
Great example here of what not to do. But I think the focus on corrections has to go back to the system and how it failed.
Friends of mine, who worked in quality control, said they were always under pressure to push the stuff out the door. Flagging bad products impeded productivity. It would be up to the customer to notice any problem and chances are they would not.
I'd be listening to this with my jaw sagging at the thought this behavior might be typical.
Years later I was upgrading memory in a computer and found that while the computer had worked for several years (expiring the warranty) that it could not work with the higher density memory that the specifications said it could. Obviously it had not been tested, but they were still able to kick it out the door and make money with it.
One place I worked I later learned typically quoted capabilities about twice what the product was capable of. Silly me, I had performed some time/motion studies on one system I had installed and estimated it could work at twice the current speed. The Salesman shushed me when I told him my results because they had sold the system quoting twice that rate. That behavior finally came back to bite them when a client said, "Show me." before they would sign off on the final payment. I calculated the system could never achieve the contracted rates. But the blame was placed on our department, rather than the salesman.
You're right, TJ, about bad news going viral. There's an old adage that an unhappy customer will tell 20 people about the bad experience, while a happy customer will tell two.
The Internet, of course, amplifies this by a thousandfold.
Wow, this is mind boggling. A tape that's supposed to have one conductive side has no conductive sides. How hard would that be to determine if properly tested for, uh, conductivity?
In each case, there were so many chances to catch the problem before it became acute.
Did engineering do enough tests before hand to prove the theory?
Did the tape meet the engineer's design specifications?
Did quality control do ANY checks?
These failures directly impact the company's name. They've at least one customer now who will not trust them, and such an anecdote has a way of going viral.
Using almost 200 light-emitting diodes in the front and back of the new 2014 CTS, Cadillac designers are showing how LEDs can change the character of a vehicle.
We looked at a number of sources to determine this year's greenest cars, from KBB to automotive trade magazines to environmental organizations. These 14 cars emerged as being great at either stretching fuel or reducing carbon footprint.
From Dell / Intel® New Paradigms in Design Work Scott Hamilton, vertical market strategist for Dell Precision workstations, 5/2/2013 3
Early in my career, I worked as a draftsman and remember the days of drawing on vellum with numbered pencils and Mylar with plastic lead. This was a fun experience in the sense that I ...
I've been using workstations for more than 10 years and love finding ways to get more performance from my system. With demanding professional applications that require more power each ...
A lasting memory from my first job as an engineer in an auto assembly plant is standing on hard concrete at six in the morning, vending-machine coffee clutched in hand, listening to ...
A quick look into the merger of two powerhouse 3D printing OEMs and the new leader in rapid prototyping solutions, Stratasys. The industrial revolution is now led by 3D printing and engineers are given the opportunity to fully maximize their design capabilities, reduce their time-to-market and functionally test prototypes cheaper, faster and easier. Bruce Bradshaw, Director of Marketing in North America, will explore the large product offering and variety of materials that will help CAD designers articulate their product design with actual, physical prototypes. This broadcast will dive deep into technical information including application specific stories from real world customers and their experiences with 3D printing. 3D Printing is
To save this item to your list of favorite Design News content so you can find it later in your Profile page, click the "Save It" button next to the item.
If you found this interesting or useful, please use the links to the services below to share it with other readers. You will need a free account with each service to share an item via that service.
Tweet This
1 
