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Drone Production Scale-Up Checklist

A practical checklist for FPV drone companies preparing for Drone Dominance orders, gauntlet down-selects, pilot builds, or full-rate production. Eleven areas where production readiness is won or lost.

Download the Checklist (PDF)Schedule a Production Readiness Review
01

BOM & revision control

  • Single controlled BOM is the source of truth — no tribal-knowledge builds
  • Revision level appears on every drawing, work instruction, and kit list
  • Engineering change process defined: who approves, how the line is notified
  • Approved component substitutions documented with equivalency rationale
02

Component sourcing & approved vendor rules

  • Approved vendor list (AVL) exists and is enforced at purchasing
  • Country-of-origin documentation collected for covered components
  • NDAA-covered component screening completed (cameras, radios, flight controllers)
  • Second sources identified for long-lead and single-source parts
03

Assembly work instructions

  • Step-level work instructions with photos for every build station
  • Torque specs, adhesive cure times, and solder standards documented
  • Operator training matrix tracks who is qualified on which station
  • Instructions versioned and synced to BOM revision
04

QC gates & acceptance criteria

  • Incoming inspection criteria defined for critical components
  • In-process QC checkpoints at high-risk assembly steps
  • Final functional test protocol with written accept/reject criteria
  • First article inspection process for every new revision
05

Serialized component tracking

  • Serial number scheme defined and applied at a fixed build step
  • Component lots linked to finished-unit serials
  • Firmware version recorded per unit at flash station
  • Test results stored against serial number, retrievable on request
06

Packaging & labeling requirements

  • Label spec confirmed with customer (format, UID, barcode symbology)
  • Manuals, inserts, and accessories on the pack-out checklist
  • Battery handling and ESD requirements documented at pack stations
  • Case-pack and palletization specs match customer routing requirements
07

Labor model & throughput assumptions

  • Takt time per unit validated by time study, not estimate
  • Line balanced across stations — no single station starves the line
  • Units-per-shift target set with yield assumption stated
  • Ramp curve defined: pilot rate → full rate, with dates
08

Rework & failure tracking

  • Defect codes defined and logged at every QC gate
  • Rework loop routes failed units through re-test, not around it
  • Scrap criteria and disposition rules written down
  • Weekly pareto review of top defects drives corrective action
09

Inventory staging & line-side replenishment

  • Kits staged ahead of the line for at least one shift of production
  • Min/max levels set for line-side consumables
  • Shortage escalation path defined — who gets called, when
  • Cycle count cadence covers high-value components
10

Fulfillment & shipping plan

  • Ship-to rules and delivery points confirmed per order type
  • Lithium battery shipping compliance verified (UN 3480/3481)
  • Serialized pack lists generated for every shipment
  • Proof-of-delivery and shipment records retained per program requirements
11

Surge capacity plan

  • Trigger thresholds defined: what order size or deadline activates surge
  • Labor surge source identified before it's needed
  • Fixtures and test stations duplicated or duplicable on short lead
  • Supplier surge commitments documented for critical components

Gaps on this list? That's what the readiness review is for.

A working session on your BOM, build process, and volumes — with the team that would run your line.

Schedule a Production Readiness Review