Pilot Runs: Crucial for Manufacturing Success

Jumping into mass production without a pilot run is like launching a rocket without a test fire, risky, costly, and likely to go wrong.

In this episode of China Manufacturing Decoded, Renaud Anjoran and Adrian from the Sofeast team break down what the pilot run process really is, why it's non-negotiable in any serious manufacturing project, and what happens when companies try to cut corners.

Suppose you're developing a new product and plan to manufacture it in China or elsewhere in Asia. This episode makes you aware of the dangers of skipping critical steps and the true purpose of pilot runs.

 

Episode Sections:

00:00 – Introduction 00:31 – Why mass production must be preceded by pilot runs 01:17 – What most companies misunderstand about being "ready" for production 02:30 – What should come after a final prototype 03:15 – Typical factory behavior in China vs. Japan/Europe 05:00 – How some Chinese factories manipulate urgency 06:30 – When fast decisions lead to irreversible mistakes 07:50 – How experienced project managers balance speed with process 10:26 – The fallacy of “shortcuts save time” 16:00 – The temptation to deliver pilot units early (and why it backfires) 17:30 – Risks of skipping pilot runs: Case studies and real-world examples 20:00 – Explaining risks to customers who want to move fast 22:32 – Customization and Risks 25:29 – Essential Pre-Production Checks 29:00 – Process improvements and learnings before mass production 30:31 – Wrap-up and further resources

 

Related content...

• What is a pilot run?
• The NPI Process: Trouble Awaits If You Skip Its Steps!
• The New Product Introduction Process Guide
• How we help you get to market faster (at our contract manufacturer)
• Pilot Run Best Practices

 

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