DeepDive 1-on-1 Series: EXECUTION READINESS - Verifying the Factory Before the Climb (30m42s)

NPI Sherpa · 10 Mar 2026 · 30m

What this episode covers

Rob Carl, Founder & CEO of Global NPI Solvers, explains how to verify factory execution readiness before mass production, warning against the 'golden road' tours that hide cultural and process gaps. He details the risks of 'perfect execution dependency,' citing the 'Moroccas' incident where uncalibrated torque drivers caused latent plastic boss failures, and discusses the importance of ESD audits and descaling assembly processes to avoid the 'golden hand' bottleneck. The conversation covers Section E (Manufacturing Execution) and Section F (Quality, Test, and Traceability), emphasizing CTQ metrics, ICT vs. functional testing, and using CPK data to prove process capability before authorizing a ramp.

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