Prototype proves a concept. Production proves a system.
Moving from prototype to production requires more than increasing quantity. The design, materials, tooling, process, tolerances, supplier, inspection, documentation, cost, lead time, and capacity all need to support repeatable manufacturing.
Each stage should reduce uncertainty before the next level of production commitment.
Concept Prototype
Evaluate basic geometry, interfaces, user interaction, mechanism, assembly, form, or functional feasibility before major production investment.
Engineering Prototype
Move closer to intended materials, tolerances, mechanical properties, electronics, joining methods, and functional performance.
Production-Intent Design
Apply DFM, finalize materials, resolve tolerance stacks, define finishes, reduce unnecessary complexity, and select the intended process.
Tooling & Process Setup
Create molds, dies, fixtures, gauges, programs, workholding, assembly aids, test systems, and production documentation.
Pilot Production
Run limited quantities using the intended production process to expose process, tooling, quality, assembly, packaging, and scheduling issues.
Production Release
Release recurring manufacturing after product, process, supplier, inspection, documentation, capacity, and commercial requirements are ready.
The prototype process and production process may solve different problems.
A printed polymer, soft material, substitute alloy, or temporary component may not represent final production behavior.
CNC machining may validate a molded product, or additive manufacturing may validate a future casting, but process-specific behavior can change.
Prototype suppliers may manually fit or adjust parts in ways that are not practical for recurring production.
Fasteners, torque, adhesives, wiring, fixtures, orientation, testing, and work sequence should become repeatable.
Production capacity should be evaluated before launch rather than after orders exceed available equipment or labor.
Use pilot builds to test the manufacturing system, not only the product.
A pilot run creates an opportunity to validate tooling, cycle time, material flow, assembly, inspection, packaging, records, supplier communication, and production assumptions before larger quantities are released.
Before launch, confirm the product and the supply system are both ready.
Design Released
Drawings, models, specifications, BOMs, materials, finishes, revisions, and approved changes should be controlled.
Process Defined
Tooling, equipment, workholding, cycle, assembly, secondary operations, testing, and packaging should be understood.
Quality Ready
Inspection methods, gauges, sampling, test requirements, first articles, acceptance criteria, and records should be established.
Supply Ready
Materials, components, supplier capacity, outside processors, lead times, forecasts, and production schedule should support launch.
Is the program ready for recurring production?
Use the manufacturing readiness checklist to review design, tooling, suppliers, quality, materials, capacity, documentation, and launch planning.
Manufacturing Readiness Checklist →