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 involves more than just logistics; it functions as a detailed audit of incoming components. During the prototype phase, materials often arrive as "Consignment" (customer-supplied), which typically includes loose cut tape, non-standar...
- 3.2 NPI Component Handling: MSL Hygiene and Feeder Readiness
In a mass production environment, components reliably arrive in factory-sealed, vacuum-packed reels. However, during New Product Introduction (NPI) prototyping, components often arrive in short cut strips, opened bags from engineering labs, or generi...
- 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 hardware assembly and software injection is a commo...
- 3.4 FAI Build Evidence Pack and MP Release
First Article Inspection (FAI) serves as the forensic audit of the manufacturing process. Its purpose extends beyond simply proving a product can be built; it demonstrates that the process is robust, repeatable, and statistically capable of scaling t...