Scaling up production: The Achilles heel of many manufacturers

Many manufacturers sustain huge economic losses as a result of inefficient scale-up from research and development (R&D) to full-scale manufacturing. These losses persist for two reasons: They do not affect traditional budget line items, and responsibility for addressing them often is poorly defined. In this white paper, Clarkston Consulting discusses techniques that can eliminate or minimize these unnecessary losses.

Common causes of scale-up losses include ill-defined responsibility for bridging the gap between R&D and manufacturing, difficult and expensive manufacturing processes due to inadequate design for manufacturability (DFM) efforts, quality issues due to inadequate failure mode analysis and failure mode and effect analysis , and increased quality problems due to improper and rushed manufacturing process development. Clarkston recommends performing these analyses on the development of all new products to reduce unnecessary losses.

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