Production Setup Consultancy
Build the factory,
not just the drone.
Most drone companies know how to design a product. Very few know how to set up a manufacturing facility that can produce it at scale — with the quality systems, certifications, and processes to match.
The production gap
Designing a drone and manufacturing it reliably are two fundamentally different problems. Moving from prototype to production demands infrastructure, quality systems, and certifications that most engineering teams haven’t built before.
01
Facility design without precedent
Laying out a production floor for drone assembly — clean rooms, battery storage zones, test areas, ESD-safe workstations — requires aerospace-grade facility planning that most startups have no experience with.
02
Quality systems from scratch
DGCA expects production quality management — incoming inspection, in-process QC, final acceptance, traceability, and CoC issuance. Building a QMS that satisfies both DGCA audits and international certification bodies is non-trivial.
03
Certification complexity
AS9100D (aerospace QMS) and ISO 9001 (general QMS) are prerequisites for credibility with defence customers, government programs, and international partners — but the certification journey is 6–12 months of structured effort.
04
Production documentation gap
Work instructions, route cards, job cards, BOM management, vendor qualification files, calibration records — the documentation infrastructure for repeatable production doesn’t exist in most prototype-stage companies.
What we set up for you
Three pillars that transform a company from prototype-stage to a certified, audit-ready manufacturing operation.
Facility & production line
Physical infrastructure — layout, equipment, tooling, workstations, safety zones, storage, and material flow — designed for drone-specific manufacturing at the scale you need.
Quality management system
Complete QMS — procedures, inspection protocols, traceability systems, supplier management, corrective actions — structured to pass both DGCA surveillance and third-party certification audits.
AS9100D & ISO 9001 certification
End-to-end certification guidance — gap analysis, documentation, internal audits, management reviews, and registrar coordination — for both AS9100D and ISO 9001.
Everything between an empty floor and a certified production line
We cover every element required to take a company from zero manufacturing capability to a fully operational, certification-ready production facility.
01
Facility layout & production line design
Floor plan optimisation, assembly station sequencing, material flow mapping, ESD-safe workstation design, dedicated zones for battery storage/charging, test areas, and incoming inspection bays.
02
Equipment & tooling selection
CNC/VMC machine specifications, assembly jig design, soldering and rework stations, test equipment selection (thrust benches, avionics testers), calibration planning, and procurement advisory.
03
Production documentation system
Work instructions, assembly procedures, route cards, job cards, production BOM management, parts kitting SOPs, configuration control, and engineering change management (ECN/ECR workflows).
04
Quality management system (QMS)
Quality manual, quality policy, incoming goods inspection (IGI) procedures, in-process QC checkpoints, final acceptance protocols, non-conformance management, CoC issuance process, and document control system.
05
Supply chain & vendor management
Vendor qualification criteria, approved supplier list, incoming inspection protocols, vendor performance monitoring, sub-contractor working arrangements, and procurement SOPs aligned to AS9100D requirements.
06
Staff training & competency framework
Training needs analysis, skill matrix development, technician certification programs, on-the-job training procedures, competency assessment records, and training effectiveness reviews.
07
Safety & regulatory compliance
Battery storage and handling SOPs, electrical safety requirements, hazardous materials procedures, fire safety planning, signage and placarding, and EHS documentation aligned to DGCA’s manufacturing facility audit checklist.
08
Packaging, dispatch & after-sales
Packaging procedures and checklists, dispatch documentation, sales register setup, UIN plate affixture SOPs, end-user record management, and warranty/service tracking systems.
Certifications we prepare you for
Two quality management certifications that give your manufacturing operation credibility with regulators, defence customers, and international partners.
AS9100D
The global quality management standard for aviation, space, and defence. Required by most defence procurement programs and international aerospace supply chains.
- Risk-based thinking and process approach
- Configuration management
- Product safety and counterfeit part prevention
- Special process control and validation
- First article inspection (FAI)
- On-time delivery and operational performance metric
ISO 9001:2015
The foundational quality management system standard recognised worldwide. Establishes the baseline processes that AS9100D builds upon.
- Process-based quality management system
- Customer focus and satisfaction monitoring
- Internal audit program
- Management review cycles
- Corrective action and continual improvement
- Document and record control
Process & timeline
A structured engagement from initial assessment to certified production. Typical duration: 8–14 months depending on facility readiness and certification scope.
analysis, roadmap
safety systems
training
closure
coordination
Who is this for?
Companies at different stages of the manufacturing journey — from greenfield to operational facilities needing certification.
Companies setting up from scratch
You have a certified drone design (or one in progress) but no manufacturing facility. You need the complete setup — facility, equipment, QMS, certifications, and trained production staff.
→ Full production setupExisting facilities needing certification
You already manufacture drones but lack a formal QMS. You need to formalise your processes, close gaps, and achieve AS9100D or ISO 9001 certification to unlock defence and export markets.
→ QMS + certification trackCompanies scaling from prototype to production
You've been building drones in small batches but need to scale to repeatable, audit-grade production — with proper documentation, inspection systems, and supply chain controls.
→ Production readiness program