MANUFACTURING READINESS
New Product Introduction Services
From Validated Design to Full-Scale Production
Synectic offers new product introduction (NPI) services that take your design through final manufacturability refinement, pilot builds, and process validation; proving your product is ready before a single unit reaches full-scale production.
A CONTROLLED APPROACH TO PRODUCTION
Reducing Risk Before Full-Scale Production
Synectic offers new product introduction services that de-risk your manufacturing process before you commit to volume production. Our on-site NPI space lets us debug and fine-tune your assembly and manufacturing process in a controlled environment first.
At its core, NPI is where we develop the manufacturing process itself, not just refine your product’s design. That means building and validating tooling, defining the assembly sequence, setting up the production line, and proving the whole system can repeatably produce your product before you commit to volume.
Because Synectic runs NPI on-site, the same team that took your design through DFM stays with it through pilot builds and its transition into full-scale contract manufacturing at Mack Molding.
OUR NPI PROCESS
Three Steps to a Validated Process
Synectic’s advantage is a cross-functional controlled manufacturing environment that is customizable for different production line layouts. We bring engineering and manufacturing together to quickly refine your product’s development and manufacturing process.
Your design is refined for manufacturability, assembly, tolerances, and cost before tooling is cut.
- Tolerance stack-up analysis
- Material & supplier selection
- Costed BOM & work instructions
Process Development
We build, test, and document pre-production units, proving the refined design translates into a repeatable process.
- Tooling, fixtures, & nest design
- MFMEA risk scoring
- Quality and manufacturing plan
Pilot Production
Traceable, sellable units validate the process under real-world conditions before full-scale launch.
- IQ, OQ, & PQ
- Qualification lots
- Process window validation
DOCUMENTATION & COMPLIANCE
Quality Documentation Built Around Your Industry
NPI produces the traceability and documentation your quality system actually requires. What that looks like changes with what you’re building:
Medical Devices
Design History File documentation, FDA-ready quality records, and ISO 13485 compliance built in from day one.
Military & Defense
MIL-STD and program-specific compliance documentation, with full traceability through pilot builds.
Food & Beverage
NSF, FDA, and UL certification documentation, with verified sanitation and food-contact material compliance.
Consumer Products
Complete testing and process documentation, scoped to what your product and customers actually need.
Robotics
FCC and UL compliance documentation, covering functional safety and risk assessment for industrial automation and human-interactive systems.
Capital Equipment
Equipment documentation and safety compliance records, including UL, CE, and OSHA requirements, validated during pilot builds.
THE FULL JOURNEY
New Product Introduction is Only One Part of the Journey
NPI is the phase between a validated prototype and full-scale manufacturing. The same Synectic team carries your product through it and into contract manufacturing without changing partners.
Need a partner for the full journey?
PORTFOLIO HIGHLIGHTS
Products Built Through Our NPI Process
FAQ
New Product Introduction - Common Questions
What's included in Synectic's NPI services?
Do you offer NPI as a standalone service, or only as part of a full product development project?
Yes. NPI is available as a standalone service if your design and prototype work is already complete elsewhere. We scope it individually based on where your project currently stands, the same way we would within a larger engagement.
Can I skip NPI and go straight from prototype to contract manufacturing?
We don’t recommend it. Skipping NPI means the manufacturing and assembly process gets validated for the first time during full-scale production, where mistakes are far more expensive. Higher scrap rates and costly assembly errors are the most common result.
How long does NPI take?
NPI generally takes 6 to 12 months, though it can run longer depending on your project’s complexity and testing requirements.
What's the difference between NPI and DFM?
What happens after NPI?
Once your process is validated through pilot production, your product moves into full-scale contract manufacturing through the Mack Group, with the same team and no partner change.
How do I get an NPI quote?
Fill out the contact form and one of our manufacturing specialists will follow up about your project.
Ready to Move Into Production?
Tell us where your project stands and we’ll map the fastest path from validated design to full-scale production.