Sample-to-production gap

The difference between a hand-built sample and production line output.

What it changes for you

The most common source of disputes - ask for a production-line sample.

In practice

The sample-to-production gap is the difference between a hand-built sample and the output of the production line. Hand-built samples hide assembly problems, so the useful sample is one taken from the line that will run your order. Where an order is large enough to justify it, a production-line sample is the only sample that predicts the batch.

Questions about Sample-to-production

Why does the production batch differ from the sample?

Usually because the sample was hand-built by an engineer, while the batch is assembled on a line by different hands with different fixtures. The gap is a process difference, not bad faith - which is why you ask for a production-line sample.

When is a production-line sample worth the cost?

Whenever a defect would cost more than the sample. On a first order or a new tooling programme it almost always is; on a repeat order of a proven specification it may not be.

Other terms

• FOB (Free On Board) - Seller delivers the goods on board the vessel at the named port; cost and risk transfer there.
• EXW (Ex Works) - Buyer collects at the factory gate.
• MOQ (Minimum Order Quantity) - The smallest quantity a factory will run for one specification.
• Tooling cost - The one-off cost of the injection mould, die or print plate.
• Colourway tolerance - The measured range a factory will hold between sample and repeat production.
• AQL (Acceptable Quality Limit) - The sampling standard (ISO 2859-1) defining allowed defects per inspected lot.

Send a specificationAll 14 terms