| 1. Need and feasibility | Intended users and use, destination markets, target requirements, existing product/IP landscape questions, technical and supplier feasibility, demand and cost assumptions, schedule, risks, and specialist needs | Approve a development brief, boundaries, owners, budget range, and investigation plan | The problem, user, market, ownership path, critical requirement, or validation route is undefined |
| 2. Architecture and requirements | System and component functions, materials, dimensions and tolerances, interfaces, performance, safety and compliance inputs, packaging, software/firmware where relevant, acceptance methods, and revision control | Authorize the requirement baseline used for design and supplier work | Requirements conflict, cannot be tested, or rely on unverified assumptions without an investigation owner |
| 3. Prototype and learning | Prototype configuration, build method, known differences from production intent, test plan, results, failures, user or technical feedback, revised risks, and change requests | Reject, repeat, change the design, or authorize tooling/industrialization planning | A prototype passes appearance review but has not tested the material technical and user assumptions it was built to test |
| 4. Design freeze and tooling release | Approved design package, bills of material, drawings and models, tolerances, specifications, test methods, design review, tooling requirements and acceptance, ownership/use terms, supplier process plan, cost and schedule | Release only the identified revision and approved tooling investment | Open technical risks, unapproved design changes, missing asset rights, or an unclear tool acceptance/transfer plan remain |
| 5. Production-intent sample and validation | Actual tool, line, materials, components, process, operators, software, test equipment, packaging, traceability, inspection, regulatory evidence, deviations, corrective actions, and stability evidence suited to the product | Approve the production configuration, require correction/revalidation, or stop | The sample used special materials, handwork, equipment, or controls that normal production will not reproduce |
| 6. First production and release | Approved configuration, production and quality plan, actual lot records, changes, inspection/test results, nonconformance dispositions, packed-cargo facts, required documents, release authority, and post-launch monitoring | Release, hold, rework, reinspect/retest, or escalate the affected scope | Schedule or sunk cost is used to bypass unresolved conformity, ownership, documentation, quality, or market-access evidence |