5 Reasons Your Product Development is Behind Schedule

product development behind schedule

Surgical Light Source for Gecko Biomedical by IDC - 12 months from brief to clinical trials

In product development, as in other areas of business, projects frequently run late which costs money and means missed opportunities. Understanding some of the most common pitfalls and how to avoid them is the key to faster, cheaper and more successful new product developments. Here are some of the most common problems and what you can do to avoid or resolve them.

1. The Specification Has Changed

Getting a clear Product Requirement Specification (PRS) or brief that is supported by the whole business is one of the most important steps that you can take in product development. Changes to the specification are consistently identified as a leading cause of delay and cost overruns. A good PRS should capture performance, size, weight and cost targets as well as standards and regulatory requirements. Make sure you understand the IP landscape and standards that the product needs to meet - these are two of the most common but avoidable reasons for late changes. Put the effort in at the beginning of the project and keep it updated and you dramatically reduce the risk of major delays.

product development behind schedule
Thermal imaging device for the National Physical Laboratory by IDC - 4 months from brief to CE certification

2. There Isn't a Detailed Plan

Planning a development project takes skill, technical knowledge and experience. A solid development plan should identify the key areas of risk and look to resolve those early whilst making reasonable allowances for potential difficulties and unknowns. Setting goals and timelines creates an urgency that focusses the team and helps identify problems at an early stage. A robust development plan should map activities, resources, timelines and even costs in detail, typically through a structured framework and a Gantt chart. Your programme should make some allowance for problems. Prototypes don’t always work perfectly first time (that’s why we make them) but by anticipating problems and planning contingencies, the disruption caused by unexpected problems can be minimised.
product development behind schedule

LiveTouch broadcast highlighting system for Quantel by IDC - 7 months from brief to tooled parts

3. People Are Putting Off Making Decisions

Delayed decisions are one of the most underestimated causes of project slippage. Designers and engineers can be guilty of wanting to constantly ‘improve’ their design. Every technical problem has more than one good design solution, so making an early, informed decision about which solution to go with can rapidly increase the speed of development. Having a clear plan with strict deadlines is an important way to get this focus. In some organisations, particularly larger ones, the time taken to align stakeholders can stretch into weeks. Each postponed decision creates a bottleneck, halting progress across multiple workstreams. Creating a focussed team with delegated authority and clear accountability to the project plan forces the team to make timely decisions without unnecessary pauses.
product development behind schedule

Axiom Injection Pen for Shaily Medical by IDC - 18 months to batches made from production tools with patent protection and freedom to operate

4. Your Supplier Isn't Delivering on Schedule

Even the best internal planning and operations can be undermined by external partners. Suppliers play a critical role in modern product manufacturing with most new developments either manufactured externally, or requiring bought-in, custom made components. Failure to select the right manufacturing partner or to manage them properly can result in long and frustrating delays. With many suppliers based in China and the Far East, a common cause of delays is getting from nearly right to a point where all the final problems are resolved. To get this done quickly and efficiently needs a team on the ground working with the factory giving rapid feedback and clearly communicating requirements. The alternative is weeks of waiting and frustration for you and the supplier as samples and emails go back and forth across the world to resolve each minor issue.

5. Your Team is Overstretched

Finally, even the most well-planned project will struggle without the right level of dedicated resource. When team members are spread across multiple priorities, progress slows, communication suffers, and accountability becomes diluted. Successful programmes are typically driven by focused teams with clear ownership and the capacity to respond quickly to challenges. Concentrated effort delivers disproportionate results, while fragmented attention almost always leads to delay and provides excuses. If your internal team doesn’t have the capacity or capability to devote to the project, consider outsourcing to a capable team with experience of similar developments.

How IDC Can Help

With experience of running hundreds of successful product developments and a success rate of 91%, IDC can help you avoid some of these pitfalls and get your project back on track. With experienced designers and engineers in UK and China we can help you:

  • Create a detailed development plan that can be successfully delivered
  • Create a robust product specification to avoid nasty surprises later in the programme
  • Manage your suppliers, including visiting Far Eastern factories to accelerate the final developments and ensure quality as you ramp up to production
  • Deliver the design and development programme, including electronics, software and mechanical engineering in partnership with your team or in its entirety

Feel free to get in touch if you would like to discuss how we can support your project.

About the Author

Stephen Knowles is the Managing Director of IDC. A chartered engineer with 25+ years experience leading technical and non-technical product developments in the medical industry. With a PhD in Mechanical Engineering and a thorough understanding of design and manufacture, Stephen is often invited to speak on the subject of product development. Contact: stephen.knowles@idc.uk.com

stephen knowles

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26 June 2026