A Pilot Run, also known as a pilot batch, is a strategic and intermediate phase in the industrialization of a new product. It serves as a “dress rehearsal” before the official start of mass production. During this stage, small quantities of the product are manufactured using the same equipment, processes, and operators intended for the final production line.
This phase is essential for identifying and correcting potential issues in the production process, validating the performance of testing systems, ensuring repeatability of results, and confirming that all technical specifications and quality requirements are met.
🎯 Main Objectives of the Pilot Run
- Validate manufacturing and assembly processes
- Adjust and validate testing and inspection systems
- Test material logistics and line supply
- Train operators and technicians
- Analyze cycle time and line capacity
- Verify compliance with quality standards (e.g., ISO, IATF)
🔍 Key Indicators Analyzed During the Pilot Run
Throughout this phase, various data points are collected to ensure the process is controlled and the product meets established criteria:
- FPY (First Pass Yield): Measures the percentage of products that pass tests without rework
- Top Failures: Identifies the most frequent defects
- CPK/PPK: Evaluates the capability of manufacturing and testing processes
- Takt Time and actual cycle time
- Analysis of rework and scrap rates
🔧 How AJOLLY Testing Supports Your Pilot Run
AJOLLY Testing offers specialized solutions to ensure the success of your Pilot Run, including:
- Development of reliable and fast testing systems
- Implementation of traceability solutions and automatic data collection
- Support in statistical analysis of results (FPY, CPK, Top Failures)
- Technical support for adjustments to test benches, jigs, and testing software
- Consulting on ergonomics and compliance with standards such as NR-12, NR-17, and ISO 9001
Our focus is to ensure your production line is ready for mass production with reliability, efficiency, and quality.
Need assistance with your Pilot Run?
Contact AJOLLY Testing to validate your testing systems and ensure a successful transition to mass production.