How to Ensure a Successful Pilot Run for Your Electromechanical Product

A pilot run is one of the most important steps in moving your electromechanical product from development into mass production. Its main purpose is to act as a test for the production run to make sure there are no major issues before you launch production. This stage is where you validate not only the product itself, but also your processes, people, and equipment.

Carrying out a production run for an electromechanical product is a bit more complicated because of the combination of mechanical, electronics, and software. If something isn’t aligned, then issues can quickly get out of control once you go into mass production. A successful pilot run helps you catch these risks early, refine your processes, and ensure that every unit coming off the line meets the same standard of quality.

In this blog, we’ll go through the key steps to set up and execute a pilot run that prepares your product for mass production.

Prepare the Right Jigs and Fixtures

As you start mass production, you will want to look at how you can create a repeatable process to ensure that each part is identical.  In development, engineers and technicians can assemble parts by hand, often making small adjustments as they go. But once you move to a pilot run, your goal is to replicate the same product multiple times, exactly the same way. This is where jigs and fixtures become essential.

Jigs and fixtures help operators assemble parts accurately and repeatedly. For example, a fixture can hold a housing in the correct orientation so components are always installed in the same position. A jig can guide screws or fasteners so they’re always aligned and tightened correctly. By eliminating variability, you not only improve quality but also speed up the assembly process.

It’s best to start with simple fixtures during the pilot run, then refine them as you collect data on operator performance and cycle times. Investing in the right tooling early will save time and reduce waste when you scale into mass production. Without them, you risk inconsistent builds, higher defect rates, and costly rework.

Develop and Share Detailed SOPs

Clear and detailed Standard Operating Procedures (SOPs) are one way to create an objective standard and to ensure consistency. They ensure that every operator follows the same steps, in the same order, using the same tools and methods. Without them, you'll start to see inconsistent builds and quality issues once production scales.

During the pilot run, your SOPs should cover each step of assembly, testing, and inspection. They need to be detailed enough to remove guesswork but simple enough that operators can follow them without confusion. Visual aids such as diagrams, photos, or annotated CAD drawings can be particularly effective for electromechanical products, where multiple components must fit together correctly.

It’s also important that SOPs are easily accessible on the production floor. Whether displayed at workstations, provided in binders, or accessible digitally, operators should never be left wondering what the next step is. A good SOP not only standardizes the process but also makes training new operators faster and more effective.

Train Operators Thoroughly

Even the best-designed product and assembly process can fail if the operators aren’t properly trained. The pilot run is the ideal opportunity to ensure that your team understands each step and can execute it consistently.

Operators should be walked through the SOPs and given hands-on practice before volume increases. During this stage, making mistakes is part of the process. What matters is catching them early and correcting them before they become ingrained habits. For electromechanical products, where wiring, torque specifications, and alignment of mechanical parts all matter, even small errors can lead to defective units.

Training also extends beyond technical skills. Operators should understand what an acceptable product looks like, how to use reference samples, and when to escalate issues to supervisors. The goal is not just to assemble the product, but to build confidence and competence that will scale with production.

Establish Clear Quality Checkpoints

Quality control during a pilot run is not just about catching defects, it’s about preventing them from moving further down the line. By setting up checkpoints at critical stages of assembly, you can identify issues early, reduce rework, and save valuable time and cost.

For electromechanical products, checkpoints might include verifying wiring harnesses before enclosure, testing sub-assemblies before final assembly, or measuring torque on fasteners before moving to the next stage. These checks act as filters, ensuring that defective components or assemblies don’t pile up and cause larger problems later in the build.

A combination of in-line inspections and final inspections works best. In-line inspections help operators correct mistakes immediately, while final inspections validate the finished product against the golden sample. The goal is to design your quality process so that defects are caught where they occur, not after dozens of units have already been completed.

Create and Use a Golden Sample

A golden sample is one part that helps to ensure consistency in the producct. It’s the reference unit that shows exactly what an acceptable product looks like. During the pilot run, it becomes one of the most valuable tools on the assembly line. Operators, engineers, and quality inspectors can all compare their work directly to the golden sample to ensure alignment on expectations.

For electromechanical products, the golden sample should reflect not only the correct fit and finish of mechanical parts but also the performance of the electronics and software. If your product involves moving parts, buttons, or displays, the golden sample should demonstrate how each should feel and function.

It’s also good practice to have a “not acceptable” sample available. By showing clear examples of defects, you help operators recognize and avoid these mistakes in real time. Together, these references create a shared understanding of what passes and what fails, eliminating subjective judgments that can lead to inconsistency.

Be Present on the Assembly Line

A pilot run is not the time for anyone, including you, to step away from the factory floor. Your presence during this stage can make the difference between a smooth transition and a troubled launch into mass production. Being available ensures that issues are identified and addressed quickly, rather than being delayed or overlooked.

Also, when engineers and decision-makers are on the line, operators feel more supported and empowered to ask questions. Small problems, like an unclear step in the SOP, a tool that isn’t working properly, or a quality concern, can be resolved on the spot before stopping the line for hours. This hands-on involvement also creates a direct feedback loop, helping you refine processes, update documentation, and make adjustments in real time.

Simply put, being present signals commitment. It shows your team and your supplier that the pilot run matters, and it sets the tone for accountability and attention to detail when production scales.

Document and Iterate

A pilot run should never be treated as a one-time exercise. It’s a learning process, and the data you gather during this stage will guide how ready you are for mass production. Every defect, delay, or adjustment is a signal for where improvements are needed.

Document yield rates, cycle times, defect types, and operator feedback. For example, if you find that wiring errors are occurring repeatedly, you might need clearer SOPs, improved fixtures, or additional training. If cycle times are longer than expected, consider whether better tooling or workstation layout could improve efficiency.

Equally important is to update your documentation as you go. SOPs, training guides, and quality checklists should reflect the improvements made during the pilot run. By iterating in this way, you lock in the lessons learned so they carry over into mass production.

The more thorough your documentation, the less likely you’ll encounter surprises when scaling up.

Conclusion: Doing the Pilot Run Right

A successful pilot run sets the foundation for everything that comes after. It’s where you prove that your electromechanical product can be built consistently, at scale, and with the quality your customers expect. By investing in the right jigs and fixtures, training operators thoroughly, providing clear SOPs, establishing quality checkpoints, and using golden samples, you create a repeatable process that eliminates variability.

Equally important is being present on the assembly line and treating the pilot run as an opportunity to learn. Documenting your findings and iterating ensures that every lesson becomes part of the production system, not just a temporary fix.

The transition from development to mass production is rarely perfect on the first try, but a well-executed pilot run gives you the confidence and clarity to scale with fewer risks. When done right, it’s not just about making the first batch of units; it’s about setting your product up for long-term success in the market.