Goldstein, Raymond (1990, ASQC) Chatsworth, CA
The need for design integrity is well recognized; however, the engineering discipline necessary to achieve it is frequently lacking. This necessitates corrections after the design is released and the manufacturing cycle has started. The cost of developing and implementing the changes is typically charged to "sustaining engineering." This is analogous to charging a manufacturing cost account for an excess quantity of products to allow for scrap, rework and repair.
The total cost of design corrections has not been quantified by many companies. Design corrections can impact deliverable products, software, logistics, manuals, customer owned products and obsolete material in stores. They frequently require customer concurrence, involving Programs Management, Contracts and Field Engineering.
The annual cost of design corrections can be in the order of millions for mid-sized companies and is worthy of senior management attention. Engineering management, supported by quality data collection and analysis, should undertake a program to identify the causes of design correction, and initiate responsive corrective actions.