Most product launch problems are predictable, and most are found too late. A practical launch checklist covering design freeze, tooling, suppliers, validation, packaging and ramp-up, so production starts on time and stays stable.
The prototypes were perfect, the customer had signed off and the launch date was in the diary. Three weeks before launch, someone asked who was supplying the shipping cartons. Nobody had ordered them. The same week, the assembly fixtures were found to suit the prototype parts but not the slightly different moulded parts, and the test equipment software was still a beta version. The product launched five weeks late, at a fraction of the planned rate.
None of these problems was technically hard. They were simply not on anyone's list.
Design freeze and documentation
- Is the design frozen, with every drawing, model and specification released at the correct revision?
- Are critical characteristics identified and carried into manufacturing documents?
- Is there a change control process from this point on?
- Are the bill of materials and approved suppliers complete and correct?
- Have tolerance stack-ups been checked on production-intent parts, not just prototypes?
Tooling and parts
- Are all tools approved, with first-article or PPAP evidence for every part?
- Have parts from the production tools been assembled and tested, not just measured?
- Are spare tool components, inserts and maintenance plans in place for critical tools?
- Are process sheets, including the scientific moulding window where relevant, documented and locked?
Suppliers and materials
- Is every purchased part, material and consumable approved and on order with confirmed lead times?
- Are minimum order quantities and safety stocks agreed?
- Are supplier quality agreements and incoming inspection plans in place?
- Has packaging been designed, tested and ordered: cartons, inserts, labels, pallets and shipping documentation?
Assembly, test and inspection
- Are assembly fixtures and tools proven with production parts?
- Is test equipment validated, with released software and gauge studies on critical tests?
- Are work instructions written, visual and trialled with the operators who will use them?
- Are inspection plans and control plans in place?
People and capacity
- Are operators, setters and inspectors trained and signed off?
- Is the line balanced to the launch volume and ramp-up plan?
- Is capacity confirmed for each step, including bottleneck processes and suppliers?
Validation and compliance
- Have design verification and production validation tests been completed?
- Are regulatory approvals, certifications and labelling complete?
- Have pilot builds been run at production rate, with issues closed out?
Ramp-up plan
- Is there a clear ramp-up curve with weekly volume and quality targets?
- Are daily reviews scheduled during ramp-up, with fast escalation of problems?
- Is engineering support on site for the first weeks?
- Is there a containment plan, such as extra inspection, until the process proves stable?
Using the checklist
A checklist is only useful if it has owners and dates. Turn each item into an action, review it weekly in the months before launch and treat any open item close to launch as a risk to be escalated, not a task to be squeezed in. Start using it at the prototype stage, when there is still time to act on what it finds.
