When managing multiple design revisions, how do you ensure effective communication between the design team and manufacturing to avoid costly production errors? My company went into a huge loss because of a lack of communication and I thought it would be nice to hear from others how they're doing it.

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You invite all stakeholders, manufacturing , assembly , included to your design reviews/tech reviews prior to releasing a new design revision. That way you ensure full oversight and all requirements are accounted for.

Secondly , you perform a trial run perhaps with prototype tooling/ parts/ processes or a combination of any. This way you can determine if there would be any issues you can predict/understand prior to signing off on hard tooling .

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I second Volvo 1. Go talk to the people who build/assembly the product. In my experience they were eager to give you their thoughts, and let you know of any challenges they might see in your design. For new engineers I stress all of the time to talk and collaborate with everyone.

Have a robust ECO process. This should include 3-D model (ipt, sldprt, stp) and drawing (idw, slddrw, dwg, dxf) revisions. It's important to know how many formats these files are saved in. The ERP system probably needs to be updated too. Manufacturing needs to know when to do with stock and in-process parts (rework or scrap). Not sure the dollar amount of the huge loss, but hopefully you guys figure it out. Good luck!

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