QualityInspection.org

27/05/2026

Hopefully, you already appreciate the importance of doing a to test all kinds of things before mass production starts, but here’s a quick recap about why it’s an essential part of the new product introduction process and some of the key points you need to plan for ahead of performing the pilot to get a successful outcome.

New product development expert, Andew Amirnovin, shares pilot run best practices with you in this post so you get good results from yours.

25/05/2026

Last week, we looked at what changes between a working prototype and mass production.
This week, part 2 follows on with the next question:
What actually goes wrong?
In this episode and blog post, Adrian and Paul look at 3 common failure patterns that can appear after prototype approval:
• A component swap that looks safe on paper
• A firmware tidy-up that creates new problems
• A factory transfer that changes the process completely
They also cover the fixes that reduce the risk:
• Configuration control
• Phase gates
• and more...

The big lesson?
A good prototype proves the concept.
It does not automatically prove the production process.

The link for you to read and listen is in the comments below!

18/05/2026

A good prototype is encouraging.
But it is not proof that production will go smoothly.
That is the point of our latest post, based on part 1 of China Manufacturing Decoded episode 328.
Before mass production starts, a lot can still change...as you're about to find out.
Hit the link below...

11/05/2026

Non-recurring engineering costs are the one-time costs needed to get a product ready for production, such as:
☛ Tooling
☛ Fixtures
☛ Testing equipment
☛ Engineering work
☛ Certifications
☛ Packaging setup
☛ Process validation

However, these don’t appear in the unit price, so they can be overlooked, which is risky, as you may miss the real upfront investment needed before production can start.
This is especially important for custom products, electronic products, and anything that needs tooling, testing, or a new production process.

Read and listen to learn more about what NRE costs are, why they matter, and how importers can plan for them before committing to a supplier. (The link is in the comments, as ever).

05/05/2026

Many hardware product development projects don’t stall because the idea is bad.
They stall because the project starts with too much missing information.

This new article/podcast episode explains why hardware projects often stall before they properly start, and what companies should clarify before moving into prototyping, tooling, or production.

The key takeaway:
Before asking “how fast can we start?”, ask “do we have enough correct information to start well?”
Link in the comments.

27/04/2026

We’ve seen some people treat a product launch as the end of the development process. In reality, it’s just the beginning.
Once a product reaches real users, a new phase begins: unexpected issues arise, assumptions are challenged, and the way customers actually use the product often differs from what was planned.
This is especially true for innovative or complex products. No matter how much testing is done during development, some risks only become visible after launch, when the product is used in real-world conditions, at scale.
In this article, we’ll look at why trying to perfect a product before launch can backfire, and how a more iterative approach, launching a solid Version 1.0, then improving based on real feedback, can reduce risk and lead to better long-term results.
Link in comments, as usual!

22/04/2026

What is the best way to familiarize yourself with the safety risks in your product category?
By checking recent recalls and lawsuits on non-compliant products similar to yours.

Here, we provide 2 good examples:
👉 An e-scooter that doesn’t even pass an EU RoHS 2 test
👉 Ladies’ underwear (specifically for periods) with ‘forever chemicals’

By seeing how things can go wrong, you can avoid the same risks in your product. (Link below in comments)

20/04/2026

If you’ve ever taken a product from idea to mass production and it didn’t go smoothly, you’re not alone. In many cases, the root cause is the same: the New Product Introduction (NPI) process WASN'T properly followed.

Take a deep dive into what the process is, and why it's so important to follow a structured process like it here. (Link in comments)

14/04/2026

Trying to design a product first…then trying to make it cheaper later is where your margins disappear (and MANY other problems can happen).

Actually, they say that up to 70% of a product’s cost is locked in during design. So if you wait until sourcing or production to work on optimizing costs, you may well be too late!

Listen to a detailed discussion about design to cost (link below).

07/04/2026

Many importers don’t get product compliance wrong on purpose.
They just think about it too late.

In this new article + podcast, we break down:
• What product compliance really involves (it’s not just CE or FCC marks)
• Why leaving it until testing creates expensive problems
• The common mistakes importers keep making
• What to do earlier to avoid failed certifications and delays

Read and listen by clicking the link in the comments.