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Modernizing Manufacturing Quality

Modernizing Manufacturing Quality

November 25, 2025 5 min read Industrials
Modernizing Manufacturing Quality

Q1. You’ve worked 30+ years in quality, operations and manufacturing — could you give a brief introduction to your current roles, responsibilities and areas you directly own?

I led quality and operational performance across multiple manufacturing environments, with direct responsibility for product release decisions, supplier quality, continuous improvement programs, and regulatory compliance. I oversee end-to-end batch quality, deviation management, CAPA execution, and manufacturing process reliability. I also drive cross-functional alignment between operations, quality, engineering, and supply chain to ensure that production, compliance, and cost-to-serve are jointly optimized. 

 

Q2. You’ve worked 30+ years in quality, operations and manufacturing — could you give a brief introduction to your current roles, responsibilities and areas you directly own?

I enabled analytics and predictive-quality models are significantly improving root-cause analysis by shortening investigation timelines and revealing multi-factor correlations that humans typically miss. We’ve seen reductions of 20–30% in deviation cycle time and faster batch-release confidence through anomaly detection.

However, the limitations that remain: data quality is often uneven, legacy instrumentation can’t provide sufficient resolution, and human expertise is still essential for final decision-making. AI accelerates reasoning — but it does not replace domain judgment. I personally developed A vision system driven by AI that can analyze up to 15 NC at a speed of 10,000 sticks per minute. 

 

Q3. With regulators tightening expectations on computerized systems (Annex-11 / data integrity), what are the most common gaps you find in site LIMS/MES/QMS implementations?

  1. Incomplete data integrity controls across interfaces — manual workarounds that are invisible to the system.
  2. Weak audit-trail culture — the system may capture changes, but teams don’t interpret and act on that data.
  3. Patchwork integrations — LIMS, MES, and QMS are implemented as separate silos rather than a unified ecosystem. The biggest priority is harmonising data models, access control, and traceability across all digital tools.

 

Q4. For sites moving from batch to continuous processing / PAT, what operational and validation challenges typically cause the biggest delays — and how did you overcome them?

The largest delays typically come from validation complexity and change-management friction:

  • Real-time release/PAT requires analytical confidence that many legacy laboratories lack.
  • Operators require retraining from static batch logic to dynamic control logic.
  • Validation protocols must be reframed to continuous-state verification rather than batch-state snapshots. 

 

Q5. Supplier quality and localisation are front-of-mind for many manufacturers — what supplier development practices deliver the fastest improvement in supplier CAPA and first-pass yield?

  • Joint problem-solving workshops using real defect data,
  • Embedding our quality engineers temporarily into supplier sites,
  • Transparent scorecards with mutual accountability,
  • And predictive quality thresholds rather than reacting to inspection failures.

This approach typically improves first-pass yield by 10–15% within 1 year. 

 

Q6. How are you integrating sustainability (material provenance, circularity) into quality release criteria — any measurement or governance approaches that work well in Europe?

We integrate sustainability into the release logic by tracking material origin, environmental footprint, and recyclability attributes as quality-linked variables. In Europe, customers and regulators increasingly demand traceability of provenance and lifecycle impact.

We use governance frameworks that treat sustainability metrics as quality attributes, not marketing claims — with quantified KPIs, supplier certification, and lifecycle documentation integrated into release criteria.

Our slogan is Safety & Sustainability FIRST, then Quality, and then Efficiency and Uptime.

 

Q7. If you were an investor evaluating a transformation project at a regulated manufacturing site, what three critical questions would you ask the management team before committing capital?

  1. What proportion of the improvement plan is technology-driven vs. behaviour-driven, and are the right capabilities in place to execute?
  2. How resilient is the supply chain — including supplier redundancy, geopolitical risk, and raw-material availability?
  3. What are the regulatory gates and compliance risks, and how early are regulators engaged in the transformation journey?

 


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