Études de cas

Du prototype à la production

Comment une marque en pleine croissance est passée de packs pilotes instables à une production de masse reproductible grâce à un contrôle structuré des spécifications.

Cas client

Du prototype à la production

Comment une marque en pleine croissance est passée de packs pilotes instables à une production de masse reproductible grâce à un contrôle structuré des spécifications.

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Consumer packaged goodsScale-up readinessFlexible pouchPrinted cartonRetail sleeveLaunch sample pack

At a glance

Customer type

Growing consumer brand preparing a multi-SKU launch after pilot packs

Packaging formats

Flexible pouch · Printed carton · Retail sleeve · Launch sample pack

Main issue

Pilot packs looked acceptable, but line consistency and supplier handoff became unstable as volume increased.

Project type

Production-readiness review

Secteurs courants

Consumer packaged goods

Region

Australia and export markets

Before

  • Pilot packs could be made, but repeatability at launch volume was unclear.
  • Teams were still debating pack details while production planning had already started.
  • Supplier risk was discovered late, when schedule pressure was highest.

After

  • Critical specs and approval samples became the shared release reference.
  • Pilot defects had owners, severity, and closure conditions.
  • The launch moved forward with clearer supplier and line-readiness gates.

What we reviewed

Approved samples, tracé de découpes, and fichiers graphiques version history
Material specifications and acceptable substitution windows
Pilot run defect notes and corrective-action evidence
Supplier process capability, lead time, and incoming inspection points

What changed

Freeze production-critical specifications

Converted dimensions, tolerances, material windows, seal targets, and approved appearance samples into controlled handoff criteria.

Close pilot defects before volume

Grouped pilot issues by structure, material, fichiers graphiques, and line setup, then defined who had to close each item before release.

Review supplier readiness

Checked incoming standards, process capability, inspection points, and fallback paths before the first full production run.

Could this apply to you?

You have a good sample but are not sure it will scale.
Sales wants to launch faster than operations feels comfortable with.
Multiple SKUs need to share one repeatable release logic.
Supplier handoff is still happening through emails and informal notes.

Timeline

Week 1

Review pilot evidence, sample status, supplier documents, and unresolved launch risks.

Weeks 2-3

Freeze critical specifications and run targeted checks for the highest-risk changes.

Release gate

Confirm production handoff package, inspection points, and issue escalation rules.

Evidence to track

Pilot-to-production closure

Track open pilot defects by severity and release status.

Supplier readiness

Track missing documents, incoming criteria, and backup-supply decisions.