What You Need to Accomplish During PVT (Production Validation Test)

PVT, or Production Validation Test, is the final build stage before entering mass production. At this point in the product development process, you're no longer testing whether parts and sub-assemblies work, that should have been resolved in earlier stages like EVT and DVT. Instead, the goal of PVT is to validate that your entire production system works.

This means using mass production tooling, final materials, and released design files. You’re running a pilot batch on the real assembly line, with production operators, Standard Operating Procedures (SOPs), Standard Inspection Procedures (SIPs), and packaging processes all in place. The goal is to confirm that your product can be manufactured at scale, with the anticipated output and quality rate. 

If successful, PVT should allow for a smooth transition directly into mass production. If there are still gaps in your documentation, tooling, or supply chain, this is the last opportunity to catch and resolve them before ramping up.

This blog outlines key accomplishments expected during the PVT stage, prior to transitioning straight into mass production.

Use Final Tools and Materials

By the time you reach PVT, all parts should be produced using mass production tooling and final materials. You should no longer be using prototype methods for mass production or temporary substitutes. This includes injection molds, die-cast tools, stamping dies, and any other production-grade tooling required to manufacture your product at scale.

Using final tools ensures that the dimensional accuracy, surface finish, tolerances, and cycle times are all representative of what you’ll see in mass production. It also allows your team to identify any wear-and-tear issues, cooling inefficiencies, or mold-release problems that may impact part quality over time.

Likewise, all materials must be the same as those approved for final production. Substituting materials during PVT defeats the purpose of validating your manufacturing process. Any change in material properties can affect how parts perform during assembly, testing, or in the hands of your customers.

If your tooling or materials are not yet final, you are not ready for PVT. Running this stage without them creates a false sense of confidence and risks missing issues that will only emerge once you scale up.

All Design Files Must Be Released for Production

PVT should only begin once all design files have been fully released for production. This means your CAD models, 2D drawings, BOMs, firmware, software, and labeling files are no longer in draft or revision stages. They’ve been approved, version-controlled, and locked in for manufacturing.

If any part of your product is still being revised, tested, or evaluated, you’re not ready for PVT  but instead still in DVT. The purpose of PVT is to validate the entire manufacturing process using the final product configuration, not to continue iterating on the design.

Running PVT without released files leads to confusion on the shop floor, incorrect builds, quality issues, and delays. It also makes it impossible to validate production documentation, work instructions, and inspection procedures, all of which rely on having a stable, final design.

In short, if your engineering team isn’t ready to freeze the design, then your production team isn’t ready for PVT.

Complete Product Certifications

Before entering PVT, all necessary product certifications must be finalized. This includes regulatory approvals such as UL, CE, FCC, RoHS, ISO, or any industry-specific requirements. 

Certifications involve performance testing, safety evaluations, and third-party inspections that can influence your design, materials, or labeling. If these requirements are not completed before PVT, you risk having to make late-stage changes that affect component selection, tooling, supply chain, or manufacturing processes. 

PVT units should be ready to ship, meaning they must be built to a certified, compliant spec. If your product fails certification after PVT, any units made will be unusable and costly to rework or scrap.

Carry Out a Pilot Run

A step that goes along with PVT is running a pilot run that mimics real production conditions. This typically involves building a small percentage of the initial production order, which uses your final tooling, materials, released files, and full assembly line setup.

The goal of this pilot run is not just to produce units, but to validate that your contract manufacturing partner can consistently build the product at scale. This includes evaluating production speed, yield rates, tooling durability, packaging workflows, and overall process reliability. It also provides a clear view into labor time, station bottlenecks, and any rework or quality issues that might arise under volume conditions.

If the pilot batch runs smoothly, it builds confidence that you’re ready to transition into mass production. If there are issues, PVT gives you the opportunity to fix them before higher production volumes lock in avoidable problems.

Validate the Supply Chain

PVT isn’t just about validating the product; it’s about validating that your entire supply chain can support full production. Every component in the BOM should be sourced from the intended production supplier, with confirmed lead times, costs, and quality standards.

This is the stage to ensure all long-lead items are accounted for, packaging materials are available, and there are no hidden gaps in the supply chain that could delay your production ramp. If any components are still being hand-sourced, temporarily substituted, or procured in small batches, the risks to your launch timeline are high.

In short, your supply chain should be production-ready, not just for this pilot run, but for the volumes that follow. If your team is still chasing parts or relying on workarounds, those problems will only grow as you scale.

Final Assembly Line Setup

During PVT, your product should be built on the final assembly line, not a temporary setup or engineering bench. This means the line must be fully configured with all production jigs, fixtures, tools, and workstations in place.

Operators should follow the final Standard Operating Procedures (SOPs) and Standard Inspection Procedures (SIPs) that will be used in mass production. These documents guide the workflow, ensure consistency, and define quality checkpoints at each stage of assembly.

This is also the time to measure takt time, assess the flow of material, and validate training processes for operators. Any issues that affect productivity or quality should be resolved during PVT, not after mass production starts.

If your factory is still improvising assembly steps or using placeholder fixtures, you're not validating the real production process. The goal is to prove that your line can build the product at the correct speed, with the correct quality, and without ongoing engineering support.

Transition Into Mass Production

The ultimate goal of PVT is to make sure you're ready to move directly into mass production without surprises. If PVT is executed correctly, no major changes should be needed after this stage. Your tooling is final, your materials are approved, your supply chain is functioning, and your assembly line is stable.

This is the moment to review key production metrics, such as yield rate, defect rate, cycle time, and throughput. You should have confidence that these metrics are sustainable and repeatable at your target volumes. If issues arise, PVT gives you the opportunity to fix them while volumes are still manageable.

At the end of PVT, many teams hold a formal production readiness review that determines whether the build can be released to mass production. When PVT is successful, you should be able to ramp immediately, knowing that your product can be built efficiently, consistently, and at scale.

Conclusion: Production Validation Test

PVT is not just another test; it’s the final proof that your product and production system are fully ready. By this stage, there should be no open engineering changes, no uncertified components, and no trial-and-error left in your process. Every part, tool, file, and station must be finalized and validated.

At EPower Corp, we guide customers through every stage of PVT, from running pilot builds with final tools and materials to validating the supply chain and setting up the production line. Our goal is to ensure a smooth, confident transition into mass production with no surprises.