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3. Process Validation & The MP Gate

Scaling a flawed process causes compounding issues. Prior to Mass Production transition, the underlying methodology must be rigorously stress-tested.

The MP Gate is a critical milestone relying on empirical proof—through First Article Inspection (FAI) reports, yield metrics, and cycle time analysis—that the manufacturing process is stable, repeatable, and capable of operating without continuous engineering intervention.

  • 3.1 NPI Supply Chain: Consignment, Kitting and Attrition

    NPI Supply Chain is more than logistics; it is a detailed audit of incoming components. In the prototype phase, materials often arrive as "Consignment" (customer-supplied), consisting of loose cut tap...

  • 3.2 NPI Component Handling: MSL Hygiene and Feeder Readiness

    In Mass Production, components reliably arrive in factory-sealed, vacuum-packed reels. In NPI prototyping, however, components often arrive in short cut strips, opened bags from engineering labs, or g...

  • 3.3 Firmware and Test Specification

    Hardware without validated firmware is largely inert matter—just silicon and copper that consumed capital but performs no function. In New Product Introduction (NPI), the synchronization of physical h...

  • 3.4 FAI Build Evidence Pack and MP Release

    First Article Inspection (FAI) is the forensic audit of the manufacturing process. It does not merely prove that a product **can** be built; it proves that the process is robust, repeatable, and stati...