How to De-Risk Your NPI Build — Before Production Even Starts

In new product introduction (NPI), the most costly setbacks often arise before the first production run. These challenges are not always due to flaws in the parts themselves, but are frequently the result of gaps in the process. Critical handoffs may be missed or mishandled, design-transfer documentation may be incomplete, supply chain contingencies may not be fully planned, or system integration points may not have been validated early enough.

When such issues surface on the production floor, they consume valuable time, budget, and momentum. The resulting delays can extend development cycles, increase the cost of goods sold, and disrupt launch schedules.

KL Engineering works with customers to reduce these risks by embedding manufacturing considerations into the product lifecycle from the earliest stages. Our approach integrates design, process, and supply chain readiness into the NPI plan without slowing innovation, enabling a smoother path from concept to full-scale production.

 

Phase 0 – Define and Align

Bring manufacturing into the conversation before CAD files are frozen or supplier POs are issued.

• Identify integration-heavy assemblies and plan for early testing.
• Flag any long-lead materials or spec-tight parts that could affect timelines.
• Align expectations on tolerances, tooling approaches, and finish requirements.

The goal here: set realistic build parameters before they become fixed constraints.

Phase 1 – Prototype with Purpose

This isn’t about making something that “just looks right” — it is about creating something that works right.

• Front-load integration-heavy subsystems to validate fit and function.
• Build prototypes with validation criteria in mind.
• Incorporate feedback from machinists, fabricators, and finishers while changes are still easy to make.

The goal here: find the friction points when fixes are still cheap and fast.

Phase 2 – Pilot for Proof

Once you’re past initial prototypes, the focus shifts to repeatability and process control.

• Confirm that critical dimensions and tolerances hold across multiple builds.
• Stress-test supply chain readiness for parts with tight sourcing windows.
• Verify that integration steps flow smoothly across teams and vendors.

The goal here: prove your build can scale without last-minute redesigns or delays.

One of the most infamous cases in aerospace highlights how early integration issues, left unchecked, can lead to catastrophic outcomes.

Parts-Level Failure in the MQ-9 Reaper Drone

A vivid illustration of how a seemingly small mechanical defect can lead to catastrophic outcomes without warning comes from a recent military mishap.

In December 2024, a $13 million MQ-9A Reaper drone crashed into the Mediterranean Sea when its propeller unexpectedly separated from the engine mid-flight. Investigators traced the failure to a mechanical issue within the Spiral Retaining Ring of the Splined Coupling Assembly—a single component failed, decoupling the propeller and leading to an unrecoverable loss of thrust and controlled flight

To quote the report, “Metal debris [was] detected in the engine oil. With indications of engine internal damage, the [pilot] shut down the engine and the [crew] executed a forced landing into the water.”

 

Why this matters for NPI risk reduction

This incident starkly illustrates how a single parts-level failure, deep in the assembly chain, can escalate into a total system failure. Had that coupling assembly—and specifically the Spiral Retaining Ring—been subjected to targeted early mechanical testing under operational loads, the failure may have been detected long before deployment.

Applying this insight to your NPI framework:

• Ensure Phase 1 prototypes are tested end-to-end, not just at subsystem level.
• Validate that all interfaces, timing sequences, and control logic work across the complete system before proceeding to pilot or production.
• Addressing these integration issues early not only avoids launch-day surprises—it can be mission critical.

Supplier Communication Strategies That Work in High-Spec Manufacturing

 

A fragmented supply chain doesn’t have to mean disconnected teams. The key is creating structured communication channels that align suppliers on priorities and risks.

• Define touchpoints early. Set scheduled checkpoints where suppliers can flag manufacturability or integration concerns before production.
• Use the common business language for specs. Misinterpretations often happen when tolerance, finish, or inspection criteria are communicated differently across vendors.
• Share key risks, not just requirements. If a part is spec-tight or supply-sensitive, ensure every vendor in the chain knows what’s at stake.
• Establish rapid feedback loops. Use quick photo or video updates to confirm build steps and avoid misalignment before shipping parts.

 

These practices ensure that even when machining, fabrication, and finishing are split between multiple vendors, the entire chain operates as if it were under one roof.

The Critical Path Mindset

Breaking NPI into these phases keeps you focused on the critical path – the parts, processes, and integration that could cause the most significant setbacks if ignored. It also means you are not leaving risk reduction until the end. Instead, you are addressing it systematically, at the exact points where it has the most impact.

The result: fewer surprises, tighter launch timelines, and a smoother ramp from prototype to production.

Let’s Build the Right Solution – Together.

At KL Engineering, capability and flexibility unite to serve one purpose: your goals. We don’t believe in one-size-fits-all. Instead, we tailor every project to fit your unique needs, seamlessly aligning with your processes and priorities. Ready to move forward with a partner who adapts to you? Visit our website or contact us today to get started on your next project: www.kle-inc.com.