What should you do when samples pass but production fails?
Direct Answer
When samples pass but production fails, the project should be reviewed for scale-up mismatch, packaging stress, filling behavior, and production readiness gaps.
Decision Interpretation
A passed sample should be interpreted as limited validation, not full production proof. When production fails, the decision must move from approval review to mismatch diagnosis.
The focus is sample approval vs production failure gap, which means the sample result must be translated into a manufacturing decision before the project moves closer to procurement readiness.
Manufacturing Risk Framing
The failure may come from hidden scale-up risk, filling speed, packaging stress, batch size, machine calibration, or stability behavior that did not appear during sample review.
This risk should be reviewed as part of the sample-to-production bridge, where sample evidence is tested against actual production constraints.
What to evaluate next
The next decision is whether the issue requires reformulation, packaging adjustment, production process change, or a pause before further production investment.
The purpose is to decide the manufacturing direction, not to treat the sample result as a final commercial decision.
Decision System Link
Decision Closure Layer
This page belongs to the sample-to-procurement bridge because it converts sample-stage evidence into manufacturing decision direction before procurement readiness is assumed.
No sample result should be interpreted alone. It should be checked against scale-up risk, packaging compatibility, filling behavior, stability expectations, and production readiness boundaries.