From Prototype to Production: 7 Pitfalls for Tech Products

You probably have already carried out the onerous work of constructing a look-alike and work-alike prototype, congratulations! Nonetheless, there are nonetheless these 7 most typical pitfalls it’s important to keep away from whereas going from prototype to manufacturing…

7 pitfalls that lie in wait earlier than you get to mass manufacturing of your electrical or mechanical product

Sadly, many individuals assume having a prototype is the ultimate step earlier than launching mass manufacturing. And, for digital and/or mechanical merchandise, that’s a harmful false impression.

Let’s study every pitfall that may badly have an effect on your plans to go from prototype to manufacturing easily right here:

1. Confirming a product design that isn’t prepared for manufacturing

Many startups hack collectively a product that’s managed by an Arduino module and enclosed in a 3D-printed plastic casing. And, since their designers haven’t any/little expertise with manufacturing processes, they don’t seem to be conscious {that a} deep re-design goes to be a should.

The rule is straightforward: so long as your design hasn’t be reviewed totally by somebody accustomed to the manufacturing processes and the supplies that might be used, you may’t assume you might be “prepared for manufacturing”. And that may require speaking to part suppliers and, typically, having them work on a ‘proof of idea’ to validate their claims.

We now have labored with groups of engineers who designed a “excellent product” and that needed to go for a really completely different idea as soon as they have been instructed its elements couldn’t be made in giant numbers at an appropriate value.

2. Going for tooling earlier than the entire product design is frozen

On the different excessive, some folks get the tooling (usually plastic injection molds) made too early. Their R&D staff reassures them — the remainder of the design is “simply getting fine-tuned”. Why not get the tooling made now, somewhat than later? It’s going to take 45+ days, so why wait?

Sadly, usually the place this occurs, there are nonetheless adjustments within the design, and in some circumstances, the tooling needs to be severely adjusted (which takes time and isn’t low-cost) and even discarded!

You may make sure decisions and pace up your product improvement, as we prompt on this article. And another decisions, like beginning too early with tooling fabrication, are seldom clever (pay attention as we talk about tooling fabrication administration and challenges on my podcast).

3. Operating a Kickstarter or Indiegogo marketing campaign too early

As I wrote in Execs and Cons of Crowdfunding (Kickstarter/Indiegogo) for Startups, crowdfunding is sort of enticing. It raises funds when it succeeds, but in addition it validates market traction and it opens new doorways.

It usually begins when you will have a pleasant prototype. Right here is how Indiegogo defines it:

Now, let’s say your marketing campaign is profitable. Your place turns into weaker on two fronts:

1. The clock is ticking. Different corporations have seen your success. Some folks would possibly resolve to develop their very own model of your idea at what they name “Shenzhen pace”… Fast & soiled, however often “doing the job” and less expensive than your providing.
2. Your individual producer additionally is aware of your again is in opposition to the wall. You’ve got promised a sure timing for transport the primary merchandise. In case your producer is aware of you may’t depart them (as you’d waste lots of time ranging from scratch with one other provider), you aren’t able of energy. That’s when notices equivalent to “the parts bought rather more costly, so we’re revising the worth up once more” develop into very doubtless.

4. Doing a crowdfunding marketing campaign and making no margin on it

Most individuals underestimate the prices they’ll incur to market, make, and ship the merchandise.

Have you ever constructed a monetary mannequin of the best way you’ll convey folks to the Kickstarter/Indiegogo web page? Will you pay Fb adverts, for instance? It’s usually costlier to make the maths work than folks think about.

And there might be sudden prices cropping up within the supplies & parts, within the packaging, within the cargo, perhaps within the customized laser engraving, and many others.

Don’t promote your product at too low a value! The concept is to gather funds that may will let you go into manufacturing.

5. Not making ready a take a look at plan for efficiency or for reliability

Is the product design actually validated? For those who haven’t constructed a testing plan and also you haven’t examined the prototypes accordingly, how would you realize?

If the product doesn’t work lengthy sufficient within the customers’ arms or doesn’t ship the efficiency they want, you’ll have to battle in opposition to unhealthy critiques. Not enjoyable!

It is very important decelerate a bit. Doc what the product does properly, and quantify that if potential. Consider how customers are doubtless to make use of the product, and the way lengthy it ought to stay in working situation. Then, plan for (reliability) life testing.

Sooner or later within the prototype stage, it’s also excellent to ship samples for accelerated life testing and to push them to failure. You’ll know the weaknesses of your design and your subsequent iteration might be higher.

6. Not forcing the producer to do a pilot run earlier than mass manufacturing

The signal of a mediocre producer is their unwillingness to do pilot runs (usually on 20 to 100 pcs solely) for validating {that a} new product might be made with out critical points.

The reason being easy. If some manufacturing or testing processes will not be prepared, the results throughout a mass manufacturing run might be very, very costly.

You probably have not mentioned this together with your meeting associate, do it now. And don’t negotiate — that’s actually necessary.

7. Failing to have the producer signal a improvement & manufacturing contract

Do you need to have visibility over the sources of the important thing parts?

Would you like the provider to be accountable if there are lots of high quality points?

Do you need to ensure the tooling actually belongs to you and also you pull it at any time?

A very good contract will assist you make your expectations clear and can elevate the percentages that you simply get what you need. Steve Dickinson, a lawyer at Harris Bricken, wrote a pleasant sequence of articles on this subject. I additionally mentioned product improvement agreements and manufacturing contracts on my podcast.

Have your say…

Have I forgotten some quite common pitfalls when going from prototype to manufacturing? Please let me know within the feedback!

Are you designing, or creating a brand new product that might be manufactured in China?

Sofeast has created An Importer’s Information to New Product Manufacturing in China for entrepreneurs, {hardware} startups, and SMEs which supplies you advance warning in regards to the 3 most typical pitfalls that may catch you out, and one of the best practices that the ‘giant corporations’ comply with that YOU can undertake for a profitable challenge together with getting from prototype to manufacturing.

Simply hit the button beneath to get your copy (please observe, this can direct you to my firm Sofeast.com):