Once a prototype has been successfully validated, the next challenge is scaling production while maintaining quality and efficiency. A pre-launch control plan serves as a bridge between development and full scale manufacturing. It ensures that processes and environmental factors are optimized, stable, and compliant with industry standards before mass production begins.
What is a Pre-Launch Control Plan?
A pre-launch control plan is an advanced quality control framework used to test and validate the manufacturing process under similar production conditions. It ensures that final design adjustments, process optimizations, and supplier readiness checks are completed before full scale production approval.
Unlike a prototype control plan, which focuses primarily on design verification, the pre-launch control plan focuses on process consistency and manufacturing feasibility.
Learn more about control plans: What is a control plan?
Key Elements of a Pre-Launch Control Plan
1. PROCESS CAPABILITY ANALYSIS (PCA)
Assessing whether the production process is stable and capable of meeting specifications.
Key Activities:
- Conducting statistical process control (SPC)
- Using Cp and Cpk values to measure process capability.
- Implementing pilot production runs to evaluate consistency.
2. DIMENSIONAL AND MATERIAL REVALIDATION
Ensuring that products match engineering specifications and material performance expectations.
Key Activities:
- Reassessing critical dimensions and tolerances.
- Verifying material properties remain consistent in scaled production.
- Conducting repeatability and reproducibility (Gage R&R) studies.
3. FINAL PERFORMANCE & RELIABILITY TESTING
Confirming that the product performs as expected in real-world conditions.
Key Activities:
- Accelerated life testing (ALT) to simulate long-term usage.
- Environmental stress testing (thermal cycling, vibration, corrosion resistance).
- Failure mode and effects analysis (FMEA) to assess risk factors.
Download Now: Control Plan Checklist
Benefits of a Pre-Launch Control Plan
- Minimize production risks and costly recalls.
- Identifies last-minute quality issues before mass production.
- Ensures supplier and material consistency.
- Optimizes manufacturing efficiency before upscaling.
A pre-launch control plan is the final checkpoint before mass production, allowing manufacturers to refine processes, validate quality controls, and ensure supply chain readiness. Investing in this critical phase prevents expensive failures and ensures that production runs smoothly from the start.
About RGBSI QLM Solutions
At RGBSI, we provide full-service quality lifecycle management (QLM) solutions that optimize manufacturing supply chain initiatives. Organizations within automotive, aerospace, and other engineering segments leverage our expertise to validate, manage, and assess their current processes.
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Looking for a QMS? Meet Empower QLM.
Empower QLM is RGBSI’s proprietary cloud-based QMS for total quality lifecycle management. From product conception through manufacturing, Empower QLM provides complete transparency by connecting all relevant parts of an enterprise to better manage processes and products.
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