Many of today’s most innovative products are being designed and prototyped in cutting-edge labs and research centers. These environments foster creativity and allow for the development of groundbreaking technologies. Unfortunately, product teams often find that their carefully designed product cannot be manufactured at scale, sending them back to the drawing board and delaying the product's journey to the market.
In this article, we will cover why, when, and how to get a manufacturing partner involved in the design process to bridge this gap and ensure successful production at scale.
But first, let’s talk about s’mores. What does this have to do with manufacturing? More than you think.
Imagine you’re tasked with making a s'more. The ingredients for this classic treat are typically two graham crackers, a marshmallow, and a piece of chocolate. The processing steps are straightforward – toast the marshmallow, then break the graham Cracker and chocolate. Finally, the assembly is simple – put chocolate on the graham cracker, put the toasted marshmallow on the chocolate, then finally sandwich with another graham cracker. Eat and enjoy!
Now, consider the scenario where I ask to make 1,000 smores. Suddenly, several questions arise. How fast can you make them? Can you guarantee repeatable results? Can you customize it to my preferences? Can you meet my price point? And what if the demand increases to 10k, 50k, or more?
The likelihood is that your design and process would need to change. This change is illustrated by the MacLeamy Curve, which shows that as a
Based on your product and internal capabilities, you can consider bringing in a manufacturing partner for several roles that align with levels of the technology readiness level (TRL) or manufacturing readiness level (MRL) scales.
Getting a manufacturing partner involved early in the design process is crucial for several reasons:
When it comes to designing for manufacturing, there are several key considerations to keep in mind.
To find a suitable manufacturing partner, start by defining your scope and manufacturing needs. This will help you narrow down potential manufacturers who specialize in your industry and can meet your requirements. Next, research manufacturers within your industry, looking at their experience, capabilities, quality systems, and compliance with industry standards. Finally, negotiate terms and agreements with the manufacturer to establish a mutually beneficial partnership.
Let’s go back to the s’mores analogy. Compared to a one-off product, here’s a hypothetical example of producing a delicious treat at scale.
As you can see, in scaled manufacturing, the process is streamlined and optimized for efficiency, repeatability, and cost-effectiveness. Materials (aka ingredients) may be substituted for equivalents that are more readily available or cost-effective, specialized equipment may be used to speed up processing, and the assembly process may be automated or semi-automated.
At Tapecon, we have experience working with product teams at all stages of development and manufacturing. Our new product introduction support includes materials selection, technical feasibility, prototyping, process validation, and more. Once the design is finalized, we offer a wide range of custom converting and printing capabilities to seamlessly transition to production. All along the way, we offer our insights and capabilities to guide and add value from the concept stage through manufacturing.
Contact us today to start a conversation about how we can support your product development journey.
With over 100 years of manufacturing experience, Tapecon works with product teams to solve challenges, create products, and enhance lives. Learn more about our new product introduction support services.