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Moving a custom COB LED from prototype to mass production requires an agreed reference, measurable acceptance limits, and a controlled change path. A sample that looks right is not yet a release baseline. The OEM and supplier must identify the design revision, materials, test results, inspection methods, and approved deviations that define the product.<\/p>\n
Tie the approved sample to controlled records, then pilot production\u00a0intent materials and processes. Define bin acceptance, product\u00a0change notices, and lot records for investigation. IHY’s published AC COB module project flow<\/strong><\/a>\u00a0lists sample evaluation and approval before contract production, followed by QC and shipment. This describes that module page, not every project’s quality controls.<\/p>\n A golden sample is the agreed physical reference for appearance, fit, and workmanship. Give it a unique ID, revision, approval date, and storage owner. Since it cannot define every electrical or optical limit, pair it with a signed specification, drawing, bill of materials, and inspection plan. State which record controls if written requirements conflict with the sample.<\/p>\n The approval record may cover substrate outline and thickness, emitting\u00a0area geometry, mounting datum, leads or connectors, and dimensions affecting the luminaire. Link these to operating current, forward\u00a0voltage range, CCT or wavelength, specified color or flux limits, and measurement conditions. Include only requirements relevant to the design.<\/p>\n Record substitutions separately. A different die, phosphor, substrate, encapsulant, or electronic component should not silently become part of the baseline. For nonstandard outlines, compare the controlled drawing with the selected custom<\/strong>\u00a0<\/strong>shape COB products<\/strong><\/a>\u00a0and confirm production samples match mounting and optical interfaces.<\/p>\n Agree where the master sample is stored and how a replacement is approved if it is damaged or altered. The sample supports judgment; measurements and written limits make it repeatable.<\/p>\n Prototype builds may receive engineering attention unavailable on every production unit. Before release, ask for a pilot using intended materials, tooling, work instructions, and inspection flow. It should test repeatability under the planned process, not just a hand\u00a0selected unit.<\/p>\n Agree what the pilot will demonstrate: for example, fit, electrical and photometric results, color consistency, thermal behavior in the intended fixture, assembly yield, or packaging. Define sample size, test setup, limits, and deviation authority. Record current, temperature, fixture, and measurement method so later lots can be compared.<\/p>\n Review failures and borderline results before release. Record the nonconformance, cause, correction, and retest. A design change requires a new revision and affected requalification; update the drawing and bill of materials with the approved sample.<\/p>\n Keep first\u00a0article approval distinct from ongoing lot inspection. The first\u00a0article record should identify the build revision and measurements used to release it. The control plan should then state inspection frequency, sampling method, equipment or fixture, acceptance criteria, and who reviews exceptions. If a process adjustment is made after approval, determine whether it affects the released baseline or requires another pilot.<\/p>\nDefine the Golden Sample in Measurable Terms<\/b><\/strong><\/h2>\n
Run a Pilot Against the Released Baseline<\/b><\/strong><\/h2>\n
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