![]() Is the pilot run an important element in your new product introduction process? How have you got on with Chinese suppliers when arranging pre-production in a way that provides better quality, cost, and lead times? Let us know in the comments. However, always remember, it is your money and you will suffer if you let them skip important steps. Perhaps they pay their operators by the piece (which means they only want to work on uninterrupted long batches).They’re often over-enthusiastic and eager to start mass production early.They might not want to spend a lot of time doing engineering work on the manufacturing.Typical Chinese suppliers avoid pilot runs for several reasons. In addition, if you are in a hurry to take delivery, the good news is, you will also get some good products faster thanks to the pilot run (but in low quantities only). Key objectives for anyone getting their products made in China. The two key benefits of conducting a pilot run/s is a lower risk assembly job and better quality products. Management of issues observed (and communication of those issues to our client) – these could be about the materials, the processes, the measurement methods, and so on.Close observations of, and improvements in, the assembly, testing, and packing processes.Operators training, along with written work instructions and examples of defects.Planning and preparation of the production processes, including internal logistics, assembly, testing, packing, and final inspection.It is the right time to set up preventive actionsĪs mentioned above, here are some of the preventive actions that we typically start setting up before the pilot run begins: This is only realistic when very large volumes are planned, with tight deadlines. Following the run, create a failure mode list and CAP (corrective action plan), then you’re able to put those in place before full production runs startĪnother best practice is to put the production line under stress by pushing throughput limits to test whether it can cope during a heavy mass production run.Set up preventive actions during the runs, such as operator training and feedback about issues to the client (see more about this later).This includes people, processes, components, machines, tools and jigs, etc Use identical conditions to mass production, otherwise, the ‘test’ is not accurate.When we perform pilot runs, we follow these best practices: However, as long as there are serious outstanding issues, the process hasn’t been confirmed and a new pilot run may be needed. The pilot run is an iterative process, much like the prototyping process. The typical number of pieces made in a pilot run? 20 to 100, depending on the size of the product and other considerations. Note, it is important to monitor the scrap rate, as it will have a direct impact on the product cost. The pilot run can also take place at the level of the component supplier (for critical components that are customized and prone to quality issues). It is called “production validation test” (PVT) in consumer electronics, “production trial run” in automotive, and so on.Īre they only useful at the point of assembly? ![]() It is a very standard approach across many industries. It is also important to confirm the assembly & packing process, including the testing stations and the inspection process. We do not skip pilot runs in these cases as they help assure that the production line and its processes work properly and can deliver products correctly once real mass production begins. This is why a short, limited production run (pilot run) is made to test the line and assure that any major kinks are ironed out.Ĭonfirming the process is capable of delivering the right quality of products is a must for all relatively new and complex products, for orders of all sizes. ![]() Defining the process is the next phase, before mass production. There are always risks when launching production of a new product. This where the pilot run becomes very important and useful. It means prototypes alone are insufficient for defining and testing the manufacturing process. However, they are usually not made with the same components, methods, equipment, people, etc. Prototypes are useful in confirming the details of the product to manufacture.
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