Why Working Prototypes Fail in Production, Part 1: What Changes Before Mass Production [Podcast]

A working prototype can give a product team a lot of confidence.

The device functions. The team signs it off. The design looks ready. Everyone starts thinking about tooling, production schedules, and launch dates.

But then production starts, and unexpected failures appear.

This is a common and costly problem in hardware development. The prototype may have worked, but that does not automatically mean the production version will work in the same way, at the same quality level, or at the intended volume.

In episode 328 of China Manufacturing Decoded, Adrian is joined by Paul Adams, Head of New Product Development, to discuss why this happens. This is part one of a two-part discussion on why working prototypes can still fail when products move toward production.

The key point is simple:

A prototype proves the concept. Production proves the process.

Those are not the same thing.

In part one, we look at what can change between prototype and production, even when the product appears identical. Paul breaks the gap down into five areas where problems often appear: components, firmware, suppliers and factories, tolerances and process variation, and the validation basis.

Listen here

Listen to the episode or watch on YouTube

Episode Sections:

• 00:00 Introduction: why working prototypes can still fail
• 02:09 Prototypes and production units are not the same thing
• 03:46 The gap between prototype and production
• 04:23 Five things that change before production
• 04:36 1 – Components: prototype parts vs production parts
• 09:17 2 – Firmware: why prototype code is not production-ready
• 12:03 3 – Suppliers and factories: why process knowledge gets lost
• 16:50 4 – Tolerances and process variation
• 19:54 5 – Validation basis: What exactly was tested?
• 22:22 Key takeaway from part one
• 23:17 What to expect in part two

Further content

• How Many Prototypes Are Needed Before We Get ‘Perfection?’
• Process Management Audit (PMA)
• An Effective New Product Development Process for Electronics
• From Prototype to Production: 7 Pitfalls for Tech Products

 Listen, rate, & subscribe to the ‘China Manufacturing Decoded’ podcast on your favorite provider

More episodes are on the way, so remember to rate us and subscribe! You can find us on:

• Apple Podcasts
• Spotify
• TuneIn
• Amazon Podcasts
• Deezer
• iHeartRADIO
• PlayerFM
• Listen Notes
• Podcast Addict
• Podchaser
• The podcast’s website at China Manufacturing Decoded