What is a Pilot Run?

The goal of any company developing a new product is to get the product into the hands of end consumers as quickly as possible. With this goal, it’s easy to have the final sample, or the golden sample, and go straight into tooling and launch mass production. During this excitement, there's a critical step that must not be overlooked, the pilot run.

Transitioning directly from prototype to full-scale production might seem efficient, especially in a fast-paced market where speed is often equated with success. However, this approach carries risks that can jeopardize quality and your total output.  

In this blog, we'll share the significance of pilot runs in mass production, exploring the goals they aim to achieve and the benefits they offer manufacturers developing products. We will also list out the goals of the pilot run and what the end result looks like. 

Why Pilot Runs Matter

When you have a golden sample, manufacturers are eager to get tools opened and get their product into the hands of the customers as quickly as possible. This may tempt manufacturers to bypass pilot runs and leap directly from prototypes to full-scale production. 

Without proper testing, companies open themselves up to a host of unexpected problems once production kicks into high gear. These issues can range from quality defects to supply chain hiccups, leading to costly setbacks and harming the product's reputation. 

Before going straight into full-scale production, it's important to conduct a trial run on a smaller scale. The volume of the production run depends on the size of the PO. However, we find a pilot run of around 10% of the PO to be a good size. Therefore, if the PO is 1,000 units then the pilot run will consist of 100 units. 

In short, skipping pilot runs not only jeopardizes product integrity but also erodes consumer trust and damages brand reputation—a costly mistake that companies should avoid at all costs.

There are 5 main reasons for the pilot run:

Risk Mitigation: Pilot runs allow companies to identify and mitigate potential risks and challenges before scaling up to full production. By testing processes, equipment, and materials on a smaller scale, companies can address issues early on and minimize the likelihood of costly setbacks. Therefore, if things do go wrong, then they go wrong on a small scale with a limited number of units. 

Quality Assurance: Conducting pilot runs enables companies to ensure that products meet quality standards and specifications before mass production begins. By thoroughly testing product integrity and performance during pilot runs, companies can minimize the risk of defects and ensure customer satisfaction.

Process Optimization: Pilot runs provide an opportunity for companies to fine-tune production processes and workflows for maximum efficiency and productivity. By analyzing data and performance metrics from pilot runs, companies can identify areas for improvement and optimize their operations before scaling up. The pilot run will identify any large bottlenecks that risk slowing down mass production.  

Supply Chain Readiness: Pilot runs help companies assess the readiness of their supply chain to support mass production. By testing the reliability and responsiveness of suppliers, as well as the resilience of logistics networks, companies can identify and address potential bottlenecks or vulnerabilities before they impact production.

Employee Training: Pilot runs gives operators and assembly workers the time to familiarize themselves with new equipment, processes, and procedures before full-scale production begins. By providing training and hands-on experience during pilot runs, companies can ensure that employees are prepared to work efficiently and effectively once production ramps up. Workers can also use this time to share with their supervisors certain steps that can be optimized or any improvements that need to be made to the Standard Operating Procedures (SOPs). 

Steps to Successfully Carry Out the Pilot Run

A successful pilot run takes time to prepare and set up. Everything necessary for production is also necessary for the pilot run but at a smaller scale. Here are the steps to carry out a successful pilot run. 

Define Objectives: Clearly outline the goals and objectives of the pilot run. What specific outcomes are you aiming to achieve? Whether it's validating production processes, assessing product quality, or optimizing costs, having clear objectives will guide the entire pilot run process.

Select Pilot Production Line: Choose a production line where the pilot run will take place. Consider factors such as equipment availability, adequate space for work in progress, and compatibility with the production process being tested.

Assemble the Team: Build a team that consists of engineers, operators, quality control specialists, and other relevant stakeholders. Collaboration and communication among team members are essential for the success of the pilot run.

Prepare Equipment and Materials: Ensure that all necessary equipment, materials, and resources are available and in working condition. Conduct maintenance checks, calibration, and testing to minimize the risk of equipment failure during the pilot run.

Gather Documentation: Compile all relevant documentation, including quality instructions, SOPs, and safety protocols. Ensure that all team members have access to these documents and are familiar with their contents.

Execute Pilot Production: Implement the pilot run according to the predefined plan. Monitor production processes closely, collect data, and document any deviations or issues encountered during the pilot run.

Conduct Quality Checks: During the pilot run, you will need to have more frequent quality checks. The importance of checking quality at every step is important to ensure only acceptable parts are moving to the next process. 

Evaluate Results and Adjustments: Analyze the data collected during the pilot run to evaluate performance against predefined objectives. Identify any inefficiencies, defects, or bottlenecks and make necessary adjustments to optimize production processes.

Document Lessons Learned: Document lessons learned from the pilot run, including successes, challenges, and recommendations for improvement. This documentation will serve as valuable insight for future pilot runs and production scaling efforts.

Review and Plan Next Steps: Hold a debriefing session with the cross-functional team to review the pilot run results and discuss next steps. Determine whether additional pilot runs or modifications to the production process are necessary before proceeding to full-scale production.

Conclusion

In mass production, pilot runs are a crucial step that helps prevent costly mistakes and unexpected problems. By testing production processes on a smaller scale, companies can catch issues early, reduce risks, and ensure a smoother transition to full-scale manufacturing. Skipping a pilot run can lead to quality problems, supply chain disruptions, and missed deadlines, which can hurt both the product and the company's reputation.

Successfully carrying out a pilot run requires careful planning and execution. From setting clear goals and assembling a skilled team to gathering documentation and conducting quality checks, each step is important to ensure the process is efficient and ready for scale-up. Following these steps helps optimize production, safeguard product quality, and prepare employees for full production.

In short, pilot runs are essential because they lay the groundwork for successful mass production. By taking the time to run a pilot test, companies can avoid risks, ensure high-quality products, and position themselves for long-term success in the market.

Interested to learn more? Reach out to Hello@epowercorp.com