Prototypes/Pathfinders have revision levels to components. Often, no 2 cars are identical P/N Rev per P/N Rev. Processes also change, so even if all Revision Levels are identical, the cars might have been produced differently. Changes to robotic CNC programs occur to optimize quality and units per hour. Prototype 5 and 6 could be revision level identical, yet, 5 took 2.1 hrs, and 6 took 1.9 hours due to programming changes.
SN01 in theory is Perfect. In reality, it is just a First Article, it can have non-conformances that need to be evaluated to determine if they need corrective action.
When SN01 is validated, corrections in processes in place, then they fire it up and make a shiitload of cars from the SN01 final process. They will continuously monitor the quality of the cars coming off the line, and make changes, but do not stop the line necessarily. Even if you've made 100,000 cars, in-process and final inspection continues, as do Rev and Process changes.
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