The jump from a working prototype to stable mass production is where many projects stumble.
Five risks to manage
- Design that is not optimised for manufacturability (DFM)
- Tolerances that drift at volume
- Unvalidated suppliers and materials
- Missing or late certification
- No pilot run before scale-up
Each risk is far cheaper to address during design than after tooling is committed. A disciplined pilot stage is the single best insurance against costly surprises.
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