Why We Push Customers to Do More Product Validation Than They Expect

Many manufacturing timelines look straightforward at the start. Two weeks for DFM, thirty days for tooling, and another thirty days for production. On paper, it feels pretty straightforward. 

Most delays that occur later in a project are not caused by poor execution, but are the result of poor planning. Issues that come up during tooling trials, early builds, or production ramp because risks were never properly addressed upfront.

The common root cause is insufficient product validation.

While most hardware companies understand the concepts of EVT, DVT, and PVT, many are less clear on what should actually be validated at each stage. We see a lot of companies cut corners to deliver on a schedule that was never really attainable in the first place. 

At EPower Corp, we push customers to validate more than they expect because it leads to better outcomes. When product validation is intentionally built into the timeline, teams reduce risk, avoid late-stage surprises, and move into production with far more confidence.

Why Product Validation Is Often Underestimated

Product validation is usually not ignored on purpose. More often, it is underestimated during planning. Teams assume that a DFM review, a few samples, or prior experience with similar products will be enough to catch issues early.

Another challenge is that validation is not always clearly defined. EVT, DVT, and PVT are familiar terms, but what actually needs to be validated at each stage is often left open to interpretation. Without clear validation objectives, teams rely on assumptions, assuming parts will assemble as expected, cosmetic quality will be acceptable, or production yields will stabilize quickly.

Schedule pressure also plays a role. When planning for validation steps, it can feel like you are pushing back the timeline. As a result, validation gets ignored, with the expectation that issues can be resolved during early production. 

But unfortunately, this approach increases risk. When product validation is ignored, problems do not magically disappear; they linger during production and affect the first order and future orders as well. 

What We Validate at Each Stage (And Why It Matters)

Product validation is most effective when it is treated as a series of focused checkpoints, not a single approval event. EVT, DVT, and PVT each serve a different purpose, and each stage is designed to surface specific risks before they impact production.

EVT: Validating the Design Concept

EVT is about confirming that the product works and that the core design decisions are sound. At this stage, validation focuses on basic functionality, key mechanical and electrical interfaces, and whether the design can realistically be assembled. Early assumptions around materials, fasteners, and critical components are also evaluated.

Issues discovered during EVT are typically inexpensive to fix. Engineering changes can be made quickly, tooling has not yet been committed, and alternative components are still viable. When EVT validation is rushed, fundamental design problems often reappear later as tooling changes or assembly issues.

DVT: Validating Manufacturability

DVT is where most hidden risks emerge. The goal is to validate that the product can be manufactured consistently, not just that it functions. This includes validating tolerances, cosmetic expectations, material behavior, and assembly sequences. It is also where early yield, rework rates, and process sensitivities start to become visible.

When DVT validation is incomplete, problems often surface after tooling is approved or during early production builds. At that point, changes require tooling modifications, extended downtime, or compromises on quality.

PVT: Validating the Production Process

PVT is about validating that the factory, not just the product, is ready for production. This stage includes tooling trials, pilot runs, and verification of the full production flow. Assembly time, staffing levels, test procedures, packaging, and quality controls are all validated under real production conditions.

PVT is where assumptions are either confirmed or disproven. Skipping or compressing this stage often leads to unstable yields, missed delivery schedules, and quality issues once volume ramps. Proper PVT validation ensures that production can scale without surprises.

Building Product Validation Into Your Timeline

Effective product validation starts during planning, not after files are released. Validation should be treated as a core part of the manufacturing timeline, with clear objectives at each stage of EVT, DVT, and PVT. When these checkpoints are defined upfront, teams know what success looks like before moving forward.

This means allocating time for iteration, feedback, and corrective actions. EVT should confirm that the design is fundamentally sound. DVT should prove that the product can be manufactured consistently and meet cosmetic and functional expectations. PVT should validate that the production line, tooling, testing, and packaging are ready to support volume.

When validation is built into the timeline, decisions become intentional rather than reactive. Teams are less likely to approve tooling prematurely or rely on early production builds to uncover issues. Instead, problems are identified when they are easier to fix and less disruptive.

A realistic timeline that includes product validation may appear longer at the start, but it reduces risk where it matters most, during production ramp and launch. This is what ultimately leads to more predictable schedules, better quality, and fewer surprises once production begins.

Conclusion: Don’t Skip the Production Validation Steps

Manufacturing delays are rarely caused by a single mistake. They are usually the result of risks that were never fully validated early in the process. When product validation is treated as an assumption instead of a plan, those risks surface later, during tooling, early production, or volume ramp, when changes are expensive and disruptive.

EVT, DVT, and PVT are not just phases to move through; they are opportunities to confirm that the product, the tooling, and the production process are ready. When teams understand what to validate at each stage and build that work into the timeline, launches become far more predictable.

At EPower Corp, we push customers to do more product validation than they expect because we have seen the alternative. Strong validation upfront reduces downstream risk, protects quality, and allows production to scale with confidence.

In manufacturing, faster launches are not achieved by skipping steps. They are achieved by validating the right things at the right time. We are happy to learn more about your product. Reach out today.