Validation Samples Before the Start of Series Production
SABNER produces validation samples as part of the implementation of a project intended for series production, not as a separate prototyping service. Their purpose is to verify key assumptions before moving to regular production: the part’s compliance with the documentation, critical project requirements, and the inspection method. During the pre-production phase, results from the first parts allow us to assess whether the process can proceed or whether corrections and re-verification are needed. SABNER focuses on projects with a target demand starting at 10,000 units per year per component.
Key Project Information
Validation Samples Are Part of a Series Production Project
SABNER does not position samples as a standalone prototyping or short-run production service. A small number of parts may be produced when needed to verify a project that is then intended to proceed to series production. A sample is therefore part of the implementation process, not the final objective of the order.
This stage allows us to verify the technical assumptions before starting regular production and to agree on any necessary corrections with the customer. In practice, the first parts produced serve as a checkpoint between the documentation and the process that will later be repeated in series production. Once the requirements are approved, the project proceeds to further preparation and series production in accordance with the established process.
Validation is intended to minimize the risk of carrying unverified assumptions over into regular deliveries. If the result meets the requirements, the project can proceed to the next stage. If a correction is needed, the scope of the changes is analyzed and agreed upon, and then re-verification is performed to the extent appropriate for the project.
Related service: precision CNC turning for series production
What Do We Check Before Starting Series Production?
The scope of validation depends on the project, but its purpose is to confirm the key assumptions before starting repeatable production. It is not about producing a few parts without a further purpose, but about gathering the information needed to make an informed decision about moving to series production. In practice, we focus on three areas: part geometry, critical requirements, and the inspection method.
Part Geometry
We verify whether the manufactured part complies with the agreed-upon documentation and whether its geometry meets the project requirements. The scope of measurements is determined by the technical documentation and the requirements agreed for the specific part. This ensures that the sample is evaluated against specific requirements rather than a general impression that the part looks correct.
Critical Requirements
We verify the requirements identified as critical to the part’s function and acceptance. These may include critical dimensions and features, tolerances, material, surface roughness, or other requirements specified in the customer’s documentation. During project preparation, it is essential to clearly identify these features, as they determine the inspection priorities and the criteria for evaluating the results.
Inspection Process
Before series production, an inspection method appropriate for the project is established. The inspection plan specifies what, how, and when measurements are taken, and the results from the process launch stage form the basis for deciding whether to proceed to series production or make corrections. This approach allows us to link the requirements from the documentation to a specific verification method. For more information about the system and our approach to quality control, visit the Quality page.
From Documentation to Series Production
Validation is not a separate process from production. It is one of the stages in preparing a project for stable series production. Its place in the process is intentional: first, the requirements and manufacturing method are established; then, the first parts are produced for evaluation; and only after a positive result does the project move on to regular production.
Documentation and Requirements
We analyze the input data, part requirements, and critical elements of the project. If the documentation requires clarification, these issues should be resolved before proceeding further with the process.
Process and Inspection Preparation
We develop the manufacturing method for the parts and the inspection criteria required before launch. At this stage, the requirements from the documentation are translated into practical manufacturing and verification procedures.
Launch and Validation
The stage may involve a First-Off, samples, or a validation batch, depending on the project requirements. Its scope is designed to correspond to what actually needs to be confirmed before series production.
Evaluation of Results
Measurement results and, where applicable, customer evaluations are analyzed. If necessary, agreed-upon corrections are made and re-verification is performed.
Series Production
After the validation stage is successfully completed, the project moves on to series production and inspection in accordance with the established process. Further production is based on the agreed-upon documentation and quality requirements.
What Happens if the Result Requires Correction?
A validation result does not always mean an immediate transition to series production. If a measurement, test, or project evaluation indicates a discrepancy, the scope of the problem and the necessary changes are first determined. After the agreed-upon correction is implemented, re-verification is performed on the elements that may have been affected by the change.
The same principle applies when documentation, geometry, material, or quality requirements change after samples have been produced. The change should be evaluated before series production to ensure that the conditions accepted during the validation phase remain valid for subsequent production.
First-Off, Samples, and Validation Batch – Scope Depends on the Project
Validation does not have to follow the same process for every project. Its scope is determined based on the documentation, quality requirements, and the objective to be confirmed before series production. Therefore, the terms “First-Off,” “samples,” and “validation batch” describe different possible scopes of the pre-production phase, not three mandatory steps in every project.
First-Off
After the process is launched, the first part is produced; its measurement results form the basis for deciding whether to release the process for further production or to make corrections and perform another First-Off. The scope of the first-part evaluation is determined by the project requirements. The First-Off itself is not a separate one-off order, but a control stage of the process launch.
Several Parts for Evaluation or Testing
If the project requires it, several parts may be produced before series production to allow the customer to verify, among other things, assembly, function, fit, or compliance with basic technical assumptions. This option is useful when a single First-Off part is insufficient to conduct the required evaluations by the project team or the customer.
Validation or Pilot Batch
In some projects, the appropriate step is a larger batch intended for validation before series production. This allows quality results to be evaluated and agreed checks to be carried out before regular deliveries begin. If the results require changes, corrections are made before the project is released for series production. The batch size is not fixed and depends on the requirements of the specific project.
What Kinds of Projects Are a Good Fit for SABNER?
SABNER focuses on CNC turning projects for series production for B2B clients. Single units or small batches are not a standard, standalone service. They may be included as a test or validation phase if the project is intended to lead to subsequent series production.
Projects that fit this model best are recurring projects with a target demand of at least 10,000 units per year per component, where regular deliveries in accordance with the technical documentation are required once the process is approved. It is also important that the part requirements can be clearly defined and verified before moving to series production.
Examples of the types of parts we produce can be found on the precision parts page. The detailed scope of our capabilities is described on the precision CNC turning service page.
Check the Scope of Our Main Service: Precision CNC Turning for Series Production
A project typically fits this model well when:
- it is intended to lead to repeatable series production rather than ending with a single unit;
- the target volume is at least 10,000 units per year per component;
- the customer has technical documentation or is prepared to clarify the requirements before production begins;
- part compliance, critical requirements, or the inspection method must be confirmed before series production.
What Should You Prepare for Project Evaluation?
For an initial assessment of the project’s feasibility and to plan validation, it is best to prepare documentation and information that allow us to define the part requirements, the evaluation method, and the target production scale. The sooner the technical and quality requirements are clearly defined, the easier it is to plan the appropriate scope of pre-production validation.
- 2D technical drawing in PDF format;
- 3D model in STEP or IGES format, if available;
- planned annual volume;
- batch size;
- critical and quality requirements for the part.
The 2D drawing is the basis for the technical evaluation, as it contains tolerances and requirements that the 3D model cannot replace. A STEP or IGES model can facilitate geometry analysis, but should not be treated as a substitute for agreed-upon dimensional documentation. If you want to organize the information contained in the documentation, see also the basics of technical drawings. The specific scope of data needed to prepare a quote depends on the project.
It is also worth providing the planned annual volume and typical batch size. This information helps assess the project not only as a one-off production run, but as a process that will later operate under series-production conditions.
If a part has features that are particularly important for its function, assembly, or quality acceptance, these should be indicated at the inquiry stage. This allows us to plan the validation process around the requirements that actually determine the project’s acceptance.
Frequently Asked Questions
Can We Order a Pilot Batch?
Yes, if the pilot batch is a preparatory stage for series production. It can be used to confirm the part’s compliance with the documentation, evaluate measurement results, and perform agreed-upon checks before launching regular production. If the results indicate a need for correction, changes can be made before the project is released for series production. The scope and batch size are determined individually for each project.
Is It Possible to Produce a Few Units First for Functional Testing?
Yes, if the few parts are intended for project validation leading to subsequent series production. Such parts can allow the customer to verify assembly, function, fit, or other requirements that need to be confirmed before series production. The number of parts and the scope of testing depend on the project. However, this is not a separate single-unit production service.
Do You Accept Orders Starting From 1 Piece?
No, not as standard, standalone production orders. SABNER specializes in CNC turning for series production. A single part or a few parts can be manufactured when they are needed as a test or validation phase for a project intended for subsequent series production. The condition is therefore that the project is ultimately intended for series production, not merely the need to produce a single part.
Once the Samples Are Approved, Do the Same Requirements Apply in Series Production?
Once the samples are approved, series production is carried out in accordance with the agreed-upon documentation, quality requirements, and established inspection method. If, following testing, the customer changes the geometry, material, or quality requirements, the change requires a reassessment of its impact on the process and production conditions. Depending on the scope of the change, revalidation of selected characteristics may be necessary before continuing series production.
Inquire About a Series Production Project
If the project is intended for series production and requires a validation phase before launch, please provide the documentation and basic requirements for evaluation. Based on this information, SABNER can assess the project’s fit with the technology, identify details that need clarification, and plan the appropriate transition from the first parts to series production.
In your inquiry, please include the target annual volume, the expected batch size, and the requirements that need to be confirmed before series production. This allows us to evaluate the project from the outset in the context of its subsequent regular production.