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Question: Dear John,  I’m having a hard time finding the right limits for our test systems. Right now we keep adjusting them, trying to find what works best through trial and error. Is there a way to quickly find the optimal limit settings to get the highest output without affecti…

Question: Dear John, What’s the difference between a pressure decay leak test and a flow-based leak test?  How do I know which one I should use?   Answer: Leak testing is one of those things that is more complicated than it seems on the surface. The differences b…

Question: Dear John,  Now that I’ve collected all this production and signature data, what can I do with it?  Answer: That data is a goldmine, just waiting to be mined.  Let’s start by looking at the pass/fail data, which can be translated into yields. Comparing …

Question: Dear John, We are a manufacturer of gas pedals assemblies. Given the recent press regarding potential problems and recalls related to gas pedals, we’ve noticed that our customers are looking for more assurances about the quality of our assemblies. Is there anything we can do on th…

Question: Dear John, How do I catch a noisy actuator on the factory floor with all that background noise? Do I need to move the part to a “quiet room”?     Answer: Well now, that’s a very good question. The problem with trying to pick up specific sounds, such as click…