30 Mar Manufacturing Conscious Product Development That De-Risks Transfer
Product design doesn’t end with feasibility. We measure success by how smoothly a design moves through verification/validation and into manufacturing transfer, supported by our process understanding, test strategy, and documentation needed to scale. That’s why we embed a manufacturing strategy at the very start of every project, not as an afterthought, but as a core part of product development.
To guide our approach, we’ve developed a set of practical principles, shaped by decades of experience, that support a successful transition from design to production, and ultimately, to market success.
Design with production in mind.
To ensure scalability, every development phase includes design for manufacturing, assembly, reliability, serviceability, and cost. These five lenses guide us from benchtop prototype to pilot line to scale-up. We design for serviceability, manufacturing tolerances, supply chain realities, testability, and assembly flow, so your pilot build doesn’t become a redesign.
Manufacturing is part of the product.
A friend once told me, “The manufacturing process is just as important as the product.” At the time, I didn’t fully appreciate it. But in medical devices, where lives are at stake, defects have to be minimized and variability must be controlled and understood. That insight continues to shape how we think about design to manufacturing. You can’t scale what you don’t understand, so we focus early on building robust, documented, testable processes that support repeatable builds and clean transfer.
Workflows are built from the bench up.
From day one, we develop scalable workflows that evolve with the product. We define the end-to-end manufacturing process, create build documentation, develop PFMEAs, and plan quality procedures (FAT, SAT, and IQ, OQ, PQ) in parallel with development. We don’t stop at theory; we build and test real assemblies, capturing lessons at each step and iterating on the process.
Pilot lines aren’t side work; they’re strategic.
As products approach trials or early production, we support clients with pilot manufacturing services tailored to the product’s unique needs. We train operators, track yield, scrap, and rework from the first units, and ensure traceability to support both regulatory and transfer-readiness goals.
Test early, test often.
In-line test strategies are introduced early to catch defects before they compound. We assess automation opportunities when they have impact, whether it’s low-volume rapid tools or semi-automated lines for scale-up. Design for Test is incorporated early in our product development process to ensure successful in-line testing.
Stay flexible, reduce risk.
Our model is different from traditional vertically integrated approaches. We avoid locking clients into rigid production pathways. Instead, we customize plans based on client goals and risk profiles. When it’s time to transfer to a contract manufacturer, we’re ready, with full documentation, guidance on CM selection and suppliers, manufacturing line layout input, and COGS modeling to help guide decisions.
Integrate, don’t isolate.
Too often, manufacturing is treated as a separate discipline to be tackled after design is complete. We see it differently. Manufacturing strategy is product strategy. It’s the difference between a novel idea and a market-ready device. Done right, it builds confidence, ensures compliance, and accelerates success.
These principles are woven into Key Tech’s culture, driven by values of ownership, collaboration, exceptional work, and real-world impact. Our “Manufacturing Solutions” offering isn’t just a service; it is how we ensure our designs transfer cleanly, scale predictably, and reach the market with fewer surprises.
Learn more about our approach to manufacturing solutions here.
Brett holds an A.A.S. in Electrical Engineering Technology, a BEng in Electrical Engineering (Magna Cum Laude), and a MEng in Industrial Engineering & Management from Arizona State University, where he also earned a Lean Six Sigma Black Belt Graduate Certificate. He is a certified Project Management Professional (PMP) and holds a CSCMP Supply Chain: Manufacturing and Service Operations Professional Certificate.
Outside of work, Brett enjoys spending time with his family and engaging in outdoor activities
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