The prototype phase is the foundation of product development. It’s where design concepts turn into tangible components, and manufacturers assess feasibility before moving to mass production. Prototype control plans help ensure quality, reliability, and compliance by defining key checkpoints for evaluation.
What is a Prototype Control Plan?
A prototype control plan is a structured document used during the prototype development phase to define quality checkpoints, measurement criteria, and validation procedures. It ensures that early-stage components are manufactured and evaluated consistently before progressing to the next phase of production.
Unlike full-scale production control plans, prototype control plans focus more on design validation rather than process control. Since changes and refinements are common in this stage, the control plan is flexible, allowing iterative improvements based on test results.
Learn more about control plans: What is a control plan?
Key Elements of a Prototype Control Plan
1. Dimensional Validation
Verifying that components match engineering drawings and design specifications.
Key Activities:
- Comparing physical dimensions to CAD drawings.
- Conducting first article inspections (FAI) to detect inconsistencies.
- Using advanced measuring tools such as coordinate measuring machines (CMM) and laser scanning.
2. Material Evaluation
Ensuring selected materials meets required standards for durability and function.
Key Activities:
- Selecting materials that improve product reliability (quality by design approach).
- Conducting chemical composition analysis (X-ray fluorescence, spectroscopy).
- Testing mechanical properties (tensile strength, hardness, fatigue).
- Simulating real world environmental conditions (temperature, humidity, corrosion).
3. Performance Testing
Evaluating the component’s functionality under simulated conditions.
Key Activities:
- Functional testing (ensuring proper operation of moving parts, electronics, etc.).
- Stress testing (evaluating endurance under extreme loads).
- Prototype failure mode and effects analysis (DFMEA and PFMEA techniques).
Download Now: Control Plan Checklist
Benefits of a Prototype Control Plan
- Early detection of design flaws – reduces redesign costs before mass production.
- Material & process validation – ensures material selection aligns with performance needs.
- Regulatory compliance – helps meet industry standards from the outset.
- Efficient iterative development – allows for informed modifications based on test feedback.
A well-executed prototype control plan ensures that products begin their journey with a strong foundation. By incorporating thorough testing and evaluations, manufacturers can confidently refine their designs and proceed to the next phase of development.
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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