What to Expect When Running Your Pilot Run in Thailand

Many companies have hit a breaking point with the ongoing tension between China and the U.S. As tariffs, trade restrictions, and political uncertainty continue to rise, they’ve been forced to migrate part or all of their production to other countries. Thailand has quickly become an option where companies can diversify their supply chain. 

For global sourcing, engineers, and supply chain teams, their first real test of manufacturing in Thailand comes in the form of a pilot run. While the purpose of a pilot run remains the same everywhere, the way it’s executed in Thailand has some key differences that global teams should understand.

Timelines are often longer, urgency levels are lower, and logistics can be more complex, especially when parts are sourced internationally. However, if you’re working with a global contract manufacturer, your engineering and quality teams may remain the same, providing consistency in documentation, validation, and quality standards.

Understanding these differences early allows teams to set realistic expectations, avoid unnecessary delays, and ensure a smooth transition from pilot to mass production.

But let’s dig into how you can prepare for the pilot run in Thailand and how they might differ from those done in China. 

Longer Timelines Are Common

One of the first differences teams notice when running pilot builds in Thailand is that timelines tend to be longer. This isn’t because the level of experience, the culture and the maturity of the supply chain lack what China has. 

Unlike China, where suppliers are pretty packed within a few miles, Thailand’s supply base is more spread out. In many cases, components are still shipped in from other countries for final assembly, which adds to the lead time. This alone can stretch the timeline of a pilot run by days or even weeks, especially when rework or replacement parts are needed.

Another factor is the working culture. While Thai production teams are skilled and capable, the overall pace is typically less urgent. That doesn’t mean work doesn’t get done, it just happens with a steadier rhythm. For companies used to extremely fast reaction times, this difference can be noticeable during pilot runs in Thailand.

To avoid delays, it’s critical to plan additional time upfront, build in buffer days for logistics, and clearly define the pilot run schedule with milestones. Companies that approach this stage with realistic expectations can maintain control of their timeline and keep their NPI launch on track.

Team Structure: Using the Same Global CM Resources

One advantage many companies have when shifting pilot runs to Thailand is that they’re often working with the same global contract manufacturer they’ve used in China. In these cases, the core engineering, quality, and operations teams remain the same. The personnel may temporarily relocate to Thailand or support the build remotely, but the standards, documentation, and processes they follow don’t change.

This consistency is valuable because the pilot run process itself doesn’t need to be reinvented. The same checklists, standard operating procedures (SOPs), and quality documentation can be applied, ensuring alignment with the original build expectations.

Where the differences are most obvious will be in the local support. The Thai production team may have less hands-on experience with pilot builds compared to China. In many cases, the China team will accompany you to Thailand to guide operators, monitor the build, and troubleshoot issues on the floor. This creates a hybrid model: experienced global engineers paired with capable Thai operators.

When managed well, this structure provides experienced pilot run oversight with local cost advantages. However, it’s important to plan for more on-the-ground involvement from your core team early in the transition, especially during the first few pilot builds.

Quality Issues and Sense of Urgency

When pilot builds take place in Thailand, quality issues can take longer to address compared to more established manufacturing hubs. This is not necessarily a reflection of capability but rather a combination of logistics, cultural working pace, and communication flow.

For many companies, critical components are still sourced internationally. If a part fails inspection or requires rework, it often needs to be shipped across borders for replacement or repair. What might be resolved in a matter of hours elsewhere can stretch into several days simply due to transit and coordination time.

Another factor is the sense of urgency. In Thailand, the working culture is generally steadier and less reactive. While teams are committed to quality and getting the job done, they may not respond to issues with the same speed some companies are used to. This can be particularly noticeable during a pilot run, where every hour matters.

If you’re using the same global engineering and quality team, they can help bridge this gap. They bring a structured approach, faster escalation, and hands-on problem-solving. This ensures that quality issues don’t linger and that decision-making remains tight.

The key is to plan for these delays upfront and create clear escalation protocols. When everyone understands the expected response times, responsibilities, and communication flow, even slower local urgency won’t derail the pilot run.

Documentation and Process Control

If you are working with a global contract manufacturer, then the documentation and process control remain consistent, regardless of where the pilot run takes place. Even when the production site shifts to Thailand, the same engineering and quality standards are typically applied.

This means your work instructions, SOPs, control plans, inspection sheets, and validation procedures should mirror what you’ve used in other locations. This consistency is critical during pilot builds, as it ensures the product and process are validated against the same criteria, helping reduce variation between sites.

In Thailand, it’s common for the local team to rely on global engineering or quality support to maintain this level of documentation discipline. This often includes daily build reviews, checklists, issue logs, and digital reporting systems. If properly structured, the pilot run can produce the same level of traceability, even if the pace and environment feel different.

It’s also important to emphasize training and communication. If operators are less familiar with the product or process, well-prepared documentation and visual aids can make the difference between a smooth build and repeated errors. Investing time upfront in proper documentation handover pays off later in fewer build interruptions.

Strategies to Run an Effective Pilot in Thailand

Running a successful pilot build in Thailand requires more upfront planning and right collaboration, and a larger buffer. The challenges, longer timelines, slower urgency, and cross-border dependencies are manageable if addressed proactively.

One of the most effective strategies is to set realistic build timelines from the start. Many companies underestimate how much additional time to budget for inbound shipments, rework cycles, and communication lags. Building buffer time into the schedule prevents unexpected issues from pushing out your production ramp.

Another smart move is to deploy experienced engineering and quality personnel to Thailand during the pilot phase. If your contract manufacturer uses the same global team, bringing them on-site (even temporarily) creates faster decision-making, better operator training, and tighter issue control.

You should also pre-stage critical parts and materials in Thailand whenever possible. Having buffer inventory of high-risk or long-lead components can save days or weeks if something goes wrong during the build.

Finally, keep documentation and communication tight. Daily pilot run reports, clear escalation channels, and shared dashboards give teams the visibility needed to keep the build moving forward, even in a different pace environment.

When planned and structured well, a pilot run in Thailand can deliver the same level of product and process validation as any other location, setting a strong foundation for a smooth production ramp-up.

Conclusion: Preparing for your Pilot Run in Thailand

Thailand is becoming a strategic location for companies diversifying their supply chains. But while the end goal may be faster delivery to market and lower tariff exposure, the pilot run phase requires a different level of planning compared to more established manufacturing hubs.

Timelines are typically longer, urgency levels are steadier, and logistics can add complexity. However, with a strong global team, structured documentation, clear communication, and a realistic build plan, these challenges are entirely manageable. In fact, many companies find that once their pilot runs are dialed in, Thailand becomes a highly stable and reliable production base.

For sourcing and engineering teams, the key is setting expectations early and preparing intentionally. A well-executed pilot run in Thailand lays the foundation for a smooth transition to mass production, stable quality, and a more resilient supply chain.