Product freeze
Both routes need the same approved product definition or a documented difference matrix.
DUAL-SOURCE MANUFACTURING
Use a second production route only when the program can support it.
Dual source is a product-transfer and quality-alignment project—not a shortcut based on country names or a fixed tariff assumption.
TRANSFER FEASIBILITY
Compare the product, supply chain and process before naming two sites.
A second route is useful only when materials, samples, work instructions, test methods and change ownership can be kept aligned. The actual factories and origin status are confirmed after supplier and program review.
Request dual-source screeningREADINESS CHECK
Six conditions that determine whether dual source is practical.
A gap does not automatically stop the program, but it creates transfer work, timing and cost that must be planned.
Material equivalence
Critical components, alternates and supplier responsibilities must be identified and approved.
Process transfer
Assembly instructions, fixtures, firmware loading, tests and workmanship criteria must be transferable.
Quality alignment
Samples, inspection methods, acceptance criteria and issue escalation need one governance plan.
Origin separation
BOM flow, labeling, records and shipping documents must support the intended origin route.
Commercial case
Forecast and repeat demand must justify duplicate setup, qualification and ongoing control.
SUITABLE CONDITIONS
When the route may be justified.
- Stable product and forecast
- Repeat demand supports two setups
- Transferable materials and process
- Buyer accepts route-specific validation
- Clear origin and document requirements
- Named owner for changes and issue closure
COMMON LIMITS
When one route may be safer.
- Product is still changing
- Volume cannot support duplicate setup
- Critical components remain single-source
- Tooling or fixtures cannot be replicated
- Quality methods are not aligned
- Origin assumptions have not been reviewed
TRANSFER ROUTE
Move from feasibility to released production.
Every gate should identify the approved baseline, open differences and responsible owner.
- 1Feasibility review
- 2Difference matrix
- 3Golden sample alignment
- 4Pilot transfer
- 5Quality correlation
- 6Route release