Creating prototypes is not enough for defining and testing the manufacturing process for your new products as they are not usually made with the same process and components as final products created in mass production. Therefore a pilot run is needed to assess whether mass production will run efficiently without problems. This presentation answers clearly: - What a pilot run is - How many pieces to make - How many runs to perform - Best practices Watch the video of this presentation here: https://youtu.be/U2hUkqqS6HU If you are currently developing a new product for manufacture in China or SE Asia, we have a range of solutions to make your life easier, save you money, and get you to market faster: https://www.sofeast.com/product-engineering-solutions/

1. NPI Process #1
Why A Pilot Run On A New Product,
Before Mass Production, Is Very
Helpful

2. Prototypes alone are insufficient for defining and
testing the manufacturing process because they are not
usually made with the same components, methods,
equipment, people, etc. as used in mass production.
This where the pilot run becomes very important and
useful.

3. What is a pilot run?
 There are always risks when launching production of a new product. Defining
the process is the next phase, before mass production. A short, limited
production run (pilot run) is made to test the line and assure that any major
kinks are ironed out early.
 Confirming the process is capable of delivering the right quality of products
and confirm the assembly & packing process is a must for all relatively new
and complex products, for orders of all sizes.
 It is a very standard approach across many industries. It is called “production
validation test” (PVT) in consumer electronics, “production trial run” in
automotive, and so on.

4. Are they only useful at the point of assembly?
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).
Note, it is important to monitor the scrap rate, as it will have a direct
impact on the product cost.

5. How many pieces would typically be made?
 The typical number of pieces made in a pilot run?
20 to 100, depending on the size of the product and other
considerations.

6. How many pilot runs should be
performed?
The pilot run is an iterative process, much like the prototyping process.
In most cases, 1 run is sufficient. However, as long as there are serious
outstanding issues, the process hasn’t been confirmed and a new pilot
run may be needed.

7. Pilot run best practices
Follow these best practices:
 Use identical conditions to mass production, otherwise, the ‘test’ is not
accurate.
 Set up preventive actions during the runs, such as operator training and
feedback about issues to the client.
 Following the run, create a failure mode list and CAP (corrective action
plan).
 Put the production line under stress by pushing throughput limits to test
whether it can cope during a heavy mass production run.

8. It is the right time to set up preventive
actions
Here are some of the preventive actions to start setting up before the pilot run
begins:
 Planning and preparation of the production processes, including internal
logistics, assembly, testing, packing, and final inspection
 Operator training, along with written work instructions and examples of defects
 Close observations of, and improvements in, the assembly, testing, and packing
processes
 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

9. Benefits
The 2 key benefits of conducting a pilot run/s are:
 A lower risk assembly job.
 Better quality products.
These are key objectives for anyone getting their products made in
China.
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).

10. Performing pilot runs in China
Typically Chinese suppliers avoid pilot runs for several reasons:
 They might not want to spend a lot of time doing engineering work on the
manufacturing
 They’re often over-enthusiastic and eager to start mass production early
 Perhaps they pay their operators by the piece (which means they only want to
work on uninterrupted long batches)
However, always remember, it is your money and you will suffer if you let them
skip important steps.

11. NPI Process #1
Why A Pilot Run On A New Product,
Before Mass Production, Is Very
Helpful