From Concept to
Mass Production, De-Risked.
Our structured NPI program bridges the gap between prototype and scale. A disciplined 12-stage framework that ensures every silicone product launches on-time, on-spec, and compliance-ready.
The NPI Framework
A 6-Phase Pipeline Engineered for Predictability
Every project flows through sequential, gated phases. No phase proceeds until the previous one is signed off by both client and YMS engineering.
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01
Engineering Review
Drawings, specs, DFM feedback
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02
Sample Approval
Prototype & golden sample
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03
Tooling & Process
Mold validation, flow setup
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04
Pilot Run
Trial & capability study
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05
SOP & Standards
Quality & workflow lock-in
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06
MP Release
Risk closure & handover
Engineering Data Confirmation
Every project begins with a rigorous review of your technical package. Our engineering team evaluates feasibility, material compatibility, and manufacturability before a single mold line is cut.
2D / 3D Drawing Review
Dimensional, tolerance, and GD&T checks against production reality.
Material Specification Match
Solid vs. LSR recommendation, hardness, color, and compliance targets.
DFM Report Delivery
Risk highlights, cost optimization opportunities, and gate location proposals.
Formal Sign-off
Locked technical baseline before any tooling investment.
Final Sample Confirmation
We produce prototype iterations until a Golden Sample is approved -- this becomes the single source of truth for all subsequent mass production.
Rapid Prototyping
3D printed, CNC or soft-tooled samples delivered within 7-14 days.
Appearance Match
Pantone-matched color, texture, finish and logo validation.
Functional Testing
Fit, assembly, use-case simulation and durability pre-check.
Golden Sample Lock
Signed, sealed and archived as reference for all QC inspections.
Tooling & Process Confirmation
Mold design, steel selection and process parameters are frozen only after validation. Precision tolerances within ±0.1 mm are guaranteed through CMM-verified mold trials.
Mold Design Review
Flow analysis, parting lines, cooling channels and venting layout verified in CAE.
Steel & Cavity Spec
P20, 718H or S136 selection matched to volume forecast and surface requirement.
T0 / T1 Trial
First-shot evaluation, dimensional CMM report and iterative mold tuning.
Parameter Lock
Temperature, pressure, cure time and cycle recorded as the official recipe.
Trial Production Preparation
Before the pilot run begins, every input -- people, machines, materials, methods and measurement -- is pre-validated against the production checklist.
Man
Operator training & QC assignment with 5+ years experience.
Machine
Line calibration, mold mounting, auxiliary equipment check.
Material
Food-grade silicone batch IRB tests, color masterbatch readiness.
Method
Work instructions, process flow and acceptance criteria issued.
Measurement
CMM, hardness tester and tensile gauge calibrated and ready.
Pilot Run -- Small Batch Trial
A controlled run of 300 - 1,000 pcs on production tooling and lines. This is the final rehearsal before mass production, surfacing any hidden process variability.
Pilot Run Objectives
- Validate process capability (CPK ≥ 1.33)
- Confirm cycle time & yield rate
- Stress-test packaging & logistics
- Collect first-article inspection report (FAI)
Deliverables After Pilot
Quality Standard Establishment
Pilot run data converts into a formal, measurable quality baseline. Every criterion is documented, approved and distributed before mass production begins.
Inspection Standards
- Appearance AQL 2.5 criteria
- Dimensional checkpoint list
- Functional pass/fail definitions
- Packaging & labeling verification
Performance Testing
- Tensile strength & elongation
- Tear resistance & impact
- Temperature & humidity aging
- Adhesion & bonding verification
Compliance Baseline
📋 Document Package
- Standard Operating Procedure (SOP) v1.0
- Work Instruction (WI) per station
- Quality Control Plan (QCP) IQC / IPQC / OQC
- Bill of Materials (BOM) locked
- Process Flow Chart approved
- Packaging Specification finalized
Production Documents & SOP
A complete controlled document set is issued and distributed to the shop floor. Every operator follows the same version, every QC uses the same checklist -- eliminating tribal knowledge and ambiguity.
Mass Production Risk Closure
Every risk identified during NPI is tracked on an open-issue log and must be closed with evidence before MP release. No open red items are allowed into mass production.
Risk Categories Addressed
8D & FMEA Methodology
For every open risk, we apply structured problem solving -- root cause analysis, corrective and preventive actions, with full traceability back to the design and process FMEA.
Mass Production Release
The final NPI gate. Both parties sign the MP Release certificate -- handover from engineering to production, with a 90-day post-launch monitoring commitment.
MP Release Certificate
Let's launch your next product -- the right way.
Share your drawings, concepts or product idea. Our NPI engineers will respond within 24 hours with a feasibility assessment and project timeline.
What to Prepare
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1Product Concept / Drawings2D, 3D (STEP/IGS), or even hand-sketched ideas
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2Target Market & ComplianceEU, US, or specific certification requirements
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3Expected Annual VolumeHelps us recommend the right tooling strategy
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4Launch DeadlineWe reverse-engineer the NPI schedule to hit your date