The transition from prototype to production is where many hardware projects encounter unexpected problems. Issues that were acceptable in prototype quantities — manual rework, component substitutions, process workarounds — become serious problems at production scale. This guide covers the key steps required to successfully make this transition.
Before committing to production, freeze your design and conduct a thorough DFM review. Changes after production has started are expensive and disruptive. The DFM review should cover PCB layout, BOM, and assembly process requirements.
If you've been using a different manufacturer for prototypes, consider running a small pilot production run (50–100 units) with your production manufacturer before committing to full production. This validates the manufacturer's processes with your specific design.
Prototype quantities can often be sourced from spot market or broker sources. Production quantities require a validated supply chain with authorized distributors and appropriate lead times.
Audit your BOM for long-lead-time components and place orders early. Identify components that are single-sourced and develop qualified alternatives. Establish minimum inventory levels for critical components.
Production requires documented processes that can be executed consistently by operators who may not have been involved in prototype development. Work with your manufacturer to document: assembly instructions for complex or unusual components, test procedures and acceptance criteria, packaging and labeling requirements, and quality control checkpoints.
Before releasing a production run, conduct a formal First Article Inspection (FAI) on the first assembled boards. The FAI verifies that the production process produces boards that meet all requirements. Document the FAI results and use them as the baseline for ongoing quality control.
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