This is a very common theme for consumer products and it happens almost during each product launch or design verification phases. Few things that can be helpful 1. Develop Modular Product Platforms: What to Do: Design products with modular components that share common manufacturing features or tolerances. How it Helps: Simplifies manufacturing and reduces the need for excessively tight tolerances. Example: A smartphone case with standardized cutouts reduces tooling changes and inspection challenges. 2. Build a Culture of Quality and Communication: Empower teams to raise concerns about unrealistic demands and offer feasible alternatives.

We have to balance between client satisfaction and operational feasibility. Here are some strategies: 1. Open Communication Educate the Client: Clearly explain the limitations of current technologies, materials, and processes. 2. Collaborative Problem-Solving Understand the Need: Dive into why the client has set such demands. Often, the ultimate goal can be met with adjusted specifications. Propose Alternatives: Offer feasible solutions or alternative specifications that meet their functional requirements. 3. Leverage Expert Consultation 4. Investing in R&D 5. Escalate Early If the demand remains inflexible and unachievable, escalate the issue to decision-makers or offer a clear refusal with reasons.

A story I experienced in China on this topic: How exactly can a 10 cm diameter shaft be manufactured by the supplier at a reasonable price, within the specified delivery time and quality according to the drawing? Not really. Because the tolerances could not be produced economically and were not even necessary for the function. But our SQE did not know what a thousandth of a millimeter was and how it affected the function. So he sent all the shipments back to the supplier. I fired him and hired someone who first had to pass a test I gave him. It consisted of several questions and a drawing from the field that had to be read carefully. We changed the drawing after consulting with the customer. Everyone was satisfied.

In precision manufacturing, I handle unrealistic quality demands by first analyzing the feasibility of the requirements and clearly communicating achievable outcomes to stakeholders. I collaborate with the quality and engineering teams to identify areas for improvement and implement advanced tools like precision measuring systems or CAD/CAM software to enhance consistency. Training plays a key role—I ensure the team is skilled in best practices to minimize errors. Additionally, I focus on continuous process optimization, such as refining machining parameters or improving tooling, to meet stringent demands while maintaining efficiency and cost-effectiveness.