PreSerienlauf

PreSerienlauf, often referred to in English as a pre-series production or pre-series run, is a phase in product development in which a limited number of units are produced on the intended production line using the final or near-final design and processes. It serves to validate manufacturing capabilities, tooling, and product performance before full-scale serial production begins. The term is commonly used in German-speaking industries such as automotive, electronics, and consumer goods.

The primary purpose of a PreSerienlauf is to assess process stability, equipment readiness, and assembly instructions under realistic production conditions. It helps qualify suppliers, determine yields and cycle times, and collect data for release decisions and quality documentation. This stage acts as a risk-mitigation step: issues found are addressed before committing to large-volume manufacturing. In automotive contexts, it may also support homologation and regulatory checks.

Typical activities during a PreSerienlauf include producing a limited batch with final or near-final tooling and materials, training operators, conducting process capability studies, and performing end-of-line tests. Documentation generated often comprises process FMEA, control plans, test reports, and validation records. The go/no-go decision resulting from the run marks the transition to serial production.

Relation to other stages: prototyping focuses on design concepts, while a PreSerienlauf tests production readiness with near-final tooling and processes. It is shorter and more limited in scope than full serial production and may vary in length from a few hundred to a few thousand units, depending on risk and regulatory requirements. In many industries, it also serves supplier qualification and early customer feedback prior to launch.