Magnetic Assembly Prototype-to-Pilot Gate Review Template

The most expensive phase in magnetic assembly programs is not always mass production. It is the handoff between approved prototype and pilot ramp.

Teams often approve prototypes on performance, then discover pilot failure modes in process control, documentation, or logistics.

Related OEM execution page: Scale-up Supply Governance.

Why prototype success does not guarantee pilot success

Prototype approval usually proves feasibility under controlled conditions. Pilot readiness requires repeatability under lot conditions, document discipline, and clear owner handoffs. Missing any of these creates hidden schedule debt.

Four-gate review framework

Use a strict gate model and require objective evidence at each step.

Gate 1: Engineering freeze

Before pilot launch, freeze:

• drawing revision and datum strategy;
• magnet orientation map and assembly sequence;
• critical-to-function tolerances and test methods;
• air-gap/concentricity assumptions where electromechanical interfaces apply.

No pilot lot should start while these are still moving.

Gate 2: Process readiness

Validate whether the process can repeat:

• fixture stability and capability for target quantity;
• inspection route and measurement system readiness;
• adhesive, curing, and balancing work instructions.

Prototype success without process readiness is not pilot readiness.

Visual: prototype-to-pilot release path

Gate 3: Quality evidence package

Require a minimum evidence set:

• CMM and runout reports with revision trace;
• balancing records under agreed test condition;
• nonconformance and corrective-action log from prototype stage.

This converts knowledge from individuals into transferable production control.

Gate 4: Compliance and shipment readiness

Pilot release must include:

• destination-specific shipping document pack;
• owner assignment for submission and updates;
• escalation path for hold/reject cases.

When this gate is skipped, finished hardware waits in inventory instead of shipping.

Pilot readiness scorecard

Use a 100-point scorecard to prevent subjective decisions:

A minimum pass score of 85 with no red gate is a practical launch baseline.

Stop-condition list

Do not release pilot lots if any condition is true:

• open CTQ without named method;
• unresolved mismatch between drawing revision and process instructions;
• balancing target defined but test speed/format undefined;
• compliance document owner not assigned.

A practical rule for launch teams

If one gate is red, the program is not ready to scale. Moving forward anyway creates hidden schedule debt that appears later as emergency rework.

A clear four-gate review keeps the team aligned and makes pilot output predictable for sourcing and integration teams.

RFQ and gate-review template block

Program: [name]
Assembly family: [rotor/stator/module]
Current revision: [rev]
Pilot lot size: [x]

Gate 1:
- CTQ matrix closed? [yes/no]
- Test method map closed? [yes/no]

Gate 2:
- Work instructions released? [yes/no]
- Measurement setup repeatable? [yes/no]

Gate 3:
- CMM/runout/balance reports complete? [yes/no]
- NCR log closed? [yes/no]

Gate 4:
- Shipment/compliance owner assigned? [yes/no]
- Document pack complete? [yes/no]

This format reduces ambiguity and gives engineering, sourcing, and QA one decision language.