Welcome to our series on the five (5) stages of the Product Development (PD) life cycle. Navigating the complexities of engineering cutting-edge technology throughout the entire product development life cycle, from initial concept to full-scale production, sets a solid foundation for a successful product launch.
In this series, we highlight the PD engineering journey to describe how integrating our engineering services with Valve Corporation helped them realize their vision to innovate VR gaming hardware to launch the Valve Index VR system. Join us as we explore the progression of the interdependent stages that underpin end-to-end engineering success.
In the previous blog, Stage 4: Design Validation, we explored vetting a product’s design to ensure manufacturing readiness. In this final blog in the series, we look at the final steps to guarantee success through production validation (PV), also called PVT (production validation testing).

Production Validation: Ensuring Quality Manufacturing at Scale
Production validation (PV) is the final stage in the product development life cycle, where the product is prepared for mass production. For Valve Corporation, this phase involved performing pilot production runs, validating the product at scale, and launching VR hardware manufacturing. AC’s expertise in production validation ensures that a product is ready for manufacturing success to the highest quality standards.
Performing pilot production run
Pilot production runs are essential for identifying and resolving any issues before full-scale manufacturing. With complex assemblies like VR hardware, testing the manufacturing process and making any necessary adjustments for production efficiency is crucial. This phase involved close collaboration with Valve’s contract manufacturers to ensure that the production lines were set up correctly and operated smoothly.
Objective: Assembly manufacturing is tested for smooth production scaling.

Validating units meet requirements at scale
Ensuring that the product meets all requirements at scale is critical for a successful launch. AC thoroughly tests pilot production units to confirm that they meet all performance, quality, and durability standards. For Valve, this meant ensuring that every unit produced delivered the same high-quality user experience as the prototypes.
Objective: Pilot units are verified as conforming to requirements and quality for production readiness.
Validating quality plan

Maintaining high-quality standards throughout production is essential for customer satisfaction. AC implemented a robust quality control plan for Valve’s VR hardware, including inspection procedures, testing protocols, and defect management processes. A well-defined quality control plan guarantees that every unit meets the highest standards of excellence.
Objective: Quality control plan is executed to manufacturing standards of excellence.
Launching the product
A successful product launch requires meticulous planning and execution. AC assisted Valve in planning and executing the launch of their VR hardware, coordinating with marketing, sales, and distribution teams to ensure a smooth rollout. This phase includes finalizing packaging, preparing marketing materials, and setting up distribution channels.
Objective: Production plan is executed for a smooth and seamless launch.

Scaling up production
Scaling up production to meet market demand is the final step in the process. AC worked with Valve to prepare for the production ramp, ensuring that the manufacturing process could be scaled efficiently without compromising quality. This involves optimizing production workflows, training assembly line workers, and establishing contingency plans to handle potential challenges.
Objective: Production efficiency and quality is maintained at scale.
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