The production ramp-up is the critical phase between the pilot and mass production. A small error can cause significant losses. Therefore, it is essential to ensure that all systems, processes, and equipment are technically validated before starting scale production.
A safe ramp-up starts with a well-structured technical checklist. And ends with stable, reliable, and traceable production.
📋 Why use a technical checklist?
- Reduces operational risks and rework
- Ensures compliance with specifications and quality standards
- Improves communication between engineering, production, quality, and maintenance
- Facilitates audits and internal releases (NPI, PPAP, ISO)
🧠 What to validate before ramp-up?
🔌 1. Equipment and test benches
- All operational jigs, with sensors, actuators, and interlocks tested
- Calibrated instrumentation (sources, multimeters, cameras, pressure switches…)
- Validated software: sequences, scripts, PLC
- Communication OK with the DUT (Ethernet, RS-485, CAN, UART, RF, Wi-Fi, etc.)
🧰 2. Process quality
- Updated technical documentation (SOP, instructions, drawings)
- Pilot tests conducted and statistical data collected (CPK, FPY, cycle time)
- Verification of common failures (Top Failures) and corrective action applied
- Reference unit (Golden/Silver Unit) tested and tracked
🧪 3. Materials and supplies
- Bill of materials (BOM) reviewed and approved
- Correct components with batch and validity
- Validated suppliers with tested deliveries
- Organized stock with FIFO and traceable batch
🧾 4. Traceability
- Integration with systems (MES, database, ERP)
- Automatic recording of serial number, results, operator, timestamp
- Test reports (PDF, XML, database) generated and archived correctly
👷 5. Operators and ergonomics
- Operators trained and certified at the stations
- Workstations with ergonomics NR-12, lighting, and layout 5S
- Production simulations at real pace with team feedback
🏭 How AJOLLY Testing supports your line’s ramp-up
At AJOLLY Testing, we apply standardized technical checklists in all automation projects, with validations that include:
- Functional testing of all tester channels
- Pilot data analysis with FPY, CPK, cycle time charts
- Creation of ramp-up control dashboards
- Complete simulation with Golden unit
- Field support during line release
📌 PDF checklist available on demand
Want a customizable technical checklist template for your project? AJOLLY Testing delivers it along with the complete system technical documentation.
Ramp-up without a checklist is like taking off without checking the engines. Do it right from the start — with engineering, traceability, and technical validation.