preparatorymanufacturing

Preparatory manufacturing is the phase before regular production begins. It includes planning, design verification, tooling and fixture development, process engineering, and facility readiness, with the aim of ensuring a smooth, economical start to production and reducing later change orders. In practice, this phase is often described as pre-production planning or setup.

Core activities cover design for manufacturability, process capability studies, equipment selection and installation, plant layout, material and supplier qualification, and procurement planning. It also encompasses budgeting, scheduling, risk assessment, and the creation of documentation such as process flows, standard operating procedures, and quality plans.

Prototyping and pilot runs validate processes and tooling, enabling adjustments before full-scale production. These activities test tolerances, yields, and process stability and often inform design changes or changes in tooling.

Digital tools are increasingly used, including PLM, CAD/CAM, ERP and MES systems, and digital twins, to support simulations, virtual commissioning, and traceability. This integration helps reduce ramp-up time and improve predictability.

Outcomes include a smoother ramp-up, fewer production disruptions, and lower total cost of ownership. Preparatory efforts require coordination among engineering, purchasing, quality, and manufacturing, and can face challenges such as time pressure and capital constraints.