Why You Shouldn’t Rush the Production Validation Test (PVT)

The Production Validation Test (PVT) is the final checkpoint before moving into mass production, yet many companies treat this validation step as optional and end up skipping it or rushing it. Sometimes, I understand this. Companies are looking to get a product into the market quickly and can feel like the top priority. However, rushing PVT often creates more problems than it solves. At this stage, you are not just validating the product itself but also the readiness of the production line, the reliability of assembly, and the repeatability of quality at scale.

When companies skip or speed through this step, they risk running into unresolved certification issues, unexpected assembly problems, and lead times that don’t match reality. Even worse, the first production run can suffer from quality failures that damage customer trust and the company’s reputation. PVT exists to prevent these outcomes, and treating it as a box to check quickly undermines the entire product launch.

What Is PVT and Why It Matters

PVT is the stage where a product transitions from prototype builds into true production. Unlike earlier EVT or DVT builds, PVT focuses less on the design itself and more on whether the production line can consistently manufacture the product at the right quality, volume, and speed.

In a PVT run, all the elements of mass production come together, the actual tooling, the supply chain, trained operators, and the assembly line setup. The goal is to confirm that the product can be produced reliably at scale and that the first units rolling off the line meet the same standards as the last.

This stage matters because it is the final opportunity to uncover process issues before customer orders are shipped. Skipping or rushing PVT means you may not have validated whether your production line is capable of handling the demands of full-scale manufacturing. In many cases, PVT is the difference between a smooth product launch and a first shipment plagued by defects, delays, and unexpected costs.

Certification Must Be Complete Before PVT

Before entering PVT, all certifications, safety, regulatory, and compliance, should already be finalized. This includes certifications such as UL, CE, FCC, or any industry-specific approvals your product requires. These certifications are not just formalities; they verify that your product meets the standards needed to enter your target markets. 

When companies rush into PVT without having certifications locked in, they take on unnecessary risk. If a certification test fails after PVT, you may need to change materials, adjust designs, or even modify tooling, all of which can invalidate the work done during the PVT run. This sets the schedule back significantly and increases costs, often erasing any time savings gained by moving too quickly.

Completing certifications first ensures that the version of your product moving through PVT is stable and compliant. That way, the PVT can focus on what it’s designed for: confirming that the production line is capable of building the certified product at scale, consistently and without surprises. Skipping this order of operations, or rushing PVT ahead of certification, can derail your entire launch plan.

Risks of Rushing PVT

Moving too quickly through the PVT can create issues that ripple across the entire product launch. While the goal of PVT is to validate the production line and ensure stability at scale, rushing PVT prevents these problems from being caught early. Some of the most common risks include:

Quality Issues

Without enough time to validate production consistency, defects may slip through unnoticed. These problems often multiply during mass production, resulting in large batches of defective units that require costly rework or scrapping.

Assembly Problems

PVT is the moment to prove that your assembly process is reliable. If skipped or rushed, small inefficiencies or misalignments in the process can become major obstacles once full-scale production ramps up.

Lead Time Misunderstanding

Many companies miscalculate their true lead time because they never validated it during PVT. Without this checkpoint, production schedules can quickly fall apart, leading to missed deadlines and delayed shipments.

Reputational Damage

If the first customer-facing production run goes poorly, the impact is more than financial. Poor quality products, delays, or recalls can damage your reputation with customers and distributors, making it harder to recover trust in future launches.

Ultimately, the risks of rushing PVT outweigh any perceived gains in speed. Taking the time to thoroughly validate this stage reduces surprises and creates a stronger foundation for mass production.

Why Companies Skip or Rush PVT

Despite its importance, many companies are tempted to skip or rush PVT. The reasons often seem practical in the moment but end up introducing greater risks later.

One of the most common motivations is time-to-market pressure. Teams feel the need to launch quickly to satisfy investors, meet demand, or stay ahead of competitors. Under that pressure, PVT can look like a step that slows things down.

Another reason is the underestimation of PVT’s value. Some companies mistakenly believe that because they’ve already passed EVT and DVT, their product is ready for production. They see PVT as redundant rather than recognizing it as a unique checkpoint focused on scaling the build process.

There’s also financial pressure. Management may want to avoid the cost of an additional production run, assuming they can save money by going straight into mass production. Ironically, skipping PVT often costs more due to rework, production stoppages, and warranty claims.

Finally, overconfidence in the design can lead companies to believe that earlier testing ensures success. But even a perfectly designed product can fail at scale if the assembly line isn’t validated.

In each case, the short-term gain of saving time or money is quickly overshadowed by the long-term risks. Rushing PVT is usually the costliest shortcut a company can take before mass production.

The Value of a Proper PVT Run

When carried out thoroughly, PVT provides benefits that extend far beyond the factory floor. Rather than being an unnecessary delay, it serves as the bridge between development builds and a smooth, reliable mass production launch.

A proper PVT run allows you to validate the stability of the production line. This includes confirming that the equipment, operators, and processes can consistently produce units at the correct quality level. It also gives visibility into whether the line can maintain that consistency over time, not just for a small batch.

PVT also helps you catch assembly inefficiencies before they become bottlenecks. By observing the process during a controlled run, you can identify areas where training, tooling adjustments, or process refinements are needed. These improvements pay dividends once the line scales up.

Another key value is accurate lead time forecasting. Instead of relying on assumptions, you gain real-world data about cycle times, yields, and throughput. This makes your production schedules more realistic and helps prevent missed deadlines.

Most importantly, a proper PVT run builds confidence. It reassures your team, your investors, and your customers that the product is ready not just to be built, but to be built at scale without compromising quality. Taking the time to validate properly reduces risk and sets up the launch for long-term success.

In short, while rushing PVT may seem like a way to save time, investing in a complete and careful PVT run ultimately saves more time, money, and reputation in the long run.

Conclusion

PVT is not just another box to check before mass production; it’s the safeguard that ensures your product, your processes, and your supply chain are ready to perform at scale. Companies that see PVT as optional or treat it as a step to rush often face the consequences later: quality failures, assembly problems, inaccurate lead times, and reputational setbacks.

By contrast, completing certifications, running a thorough PVT, and addressing issues uncovered during the process provide the stability needed for a smooth product launch. The time invested here prevents costly mistakes down the line and positions your first mass production run for success.

In manufacturing, speed to market matters, but only if it’s supported by quality and reliability. Rushing PVT may look like a shortcut, but in reality, it can derail your launch. The smarter path is to treat PVT as an investment in protecting your product, your customers, and your brand.