Product Manufacturing 101


This unique workshop is designed to accelerate the commercialization and scale up of “hardware” physical product developers. It is recommended for start-ups and anyone who wants to prove out their design before beginning production.

The workshop introduces design for manufacturability and lean product design concepts utilizing a structured methodology for evaluating your Bill of Materials (BOM), how your product is produced or Bill of Process (BOP) and defining your potential failure modes.

This 1-day session will focus on how to move from proof-of-concept to alpha and beta prototypes to production scale using tangible exercises that directly support your company. You will identify and develop solutions to potential manufacturability issues early on that could prohibit commercialization and long-term viability. The session is designed to help you evaluate where your technology could benefit from a redesign early on to reduce complexity, thereby reducing cost, and provide a roadmap for leaning your product design.

Outcomes of the 101 workshop include Design for X principles, defining your BOM, BOP, potential failure modes and structure for a next generation product development and test plan. The program allows time for meaningful 1-on-1 meetings with instructors and manufacturing experts to provide individual and direct support for your team.


0830 - 0900 | Registration

0900 - 0930 | Program Overview & Introductions

0930 - 1000 | Designing Your Product for X (Workshop Exercise)

1000 - 1045 | Developing Your Bill of Materials (Workshop Exercise)

1045 - 1100 | Break

1100 - 1200 | Developing Your Manufacturing Bill of Process (Workshop Exercise)

1200 - 0100 | Working Lunch: Leaning Your Product Design (Workshop Exercise)

0100 - 0130 | Moving from Alpha/Beta Prototypes to Manufacturing at Scale

0130 - 0200 | Design for Failure Mode and Effects Analysis (Workshop Exercise)

0200 - 0300 | Mentorship & Coaching: One-on-One with Instructors

To get the most out of FuzeHub's resources and jump-start your journey to product commercialization, check our training schedule, register for an event, and consider becoming a FuzeHub Build4Scale-NY Member.

Module Descriptions

Designing Your Product for X

This module helps prioritize your product design utilizing case studies and a workshop exercise. Each participant will identify, evaluate and prioritize designing their product for customer use, market acceptance, manufacturability, assembly, durability, reliability, installation, maintenance, logistics.

Developing a Strategic Bill of Materials (BOM)

The module provides the foundation for helping structure an intelligent bill of materials that not only lists all the parts and materials needed to create your product but also supports an accurate determination of your cost of goods sold, cash flow requirements, parts numbering, parts revisions/variations, lead-time estimates, quality tracing, quote timing, etc. Each participant will construct the foundation for their intelligent bill of materials during the workshop and can use it going forward as a product development planning tool.

Developing a Strategic Bill of Process (BOP)

The module provides a unique methodology for developing an intelligent bill of process, a step by step production map for assembling your product including the parts, tools, machines and operations needed to assemble a given product design. This includes a workshop exercise where each participant will map their production process and can use it going forward as a product development planning tool.

Leaning Your Product Design

The module provides a unique methodology for taking a critical assessment of your product design in an effort to reduce complexity and drive out cost. Each participant is guided through a “Parts Value Challenge” exercise that challenges your product design to minimize the number of parts, minimize the number of process steps, design out parts that commonly fail, and target multi-touch operations for process step reductions.

Moving from Proof of Concept to Alpha/Beat Prototypes to Production

The module addresses key questions to consider when designing and testing your next generation prototype or product launch. The session will provide insight on the most common mistakes to avoid, and how to avoid the development of several prototype modifications.

Next Generation Product Design Planning

The module provides a Manufacturing Risk Assessment to support your next generation prototype or product launch. Participants will engage in a Design for Failure Mode and Effects Analysis (DFMEA) exercise that helps determine potential failures in their design, determine the potential for occurrence, severity and detection, and through a unique scoring system determine the potential failures to prioritize for attention in their product development and test plan.