8-Stage Drone Assembly Standard Operating Procedure
Standardized step-by-step manufacturing workflow executed across our Waluj and Paithan facilities to ensure 100% mechanical integrity, electrical insulation, and flight stability.
The Absolute Stop-Work Rule
Any damaged battery cell, unexpected heating, wiring uncertainty, loose motor mount fastener, GNSS compass interference, fluid leak near avionics, or unexplained flight controller warning means STOP IMMEDIATELY. Disconnect main power, isolate unit to battery quarantine bunker, tag defect with red label, and record root cause before resumption.
8-Stage Aerospace Drone Assembly Workflow
Precision engineering protocols deployed at Waluj Assembly Plant with rigorous Quality Gates (G1–G8).
Frame Preparation & Torque Rigging
Inspect carbon composite plates, install landing gear struts, fit 30mm boom clamps, and torque all aerospace M3/M4 fasteners to precisely 2.8 Nm using calibrated drivers.
H1: Verify propulsion structural clearance before motor mounting.
Stop work immediately if any carbon spar shows hairline cracks, delamination, or fastener thread stripped.
Engineering Hold Points (H1 – H4)
Propulsion Mass Hold Point
Do not purchase or install propulsion components until total loaded all-up mass (AUW) is verified and thrust margins exceed 2.2:1.
Electrical Polarity Hold Point
Do not connect flight battery until polarity, wire gauge, XT90 spark suppression, and main fuse ratings undergo independent 2-person signoff.
Bench Electronics Failsafe Hold Point
Do not install propellers during any indoor bench electronics, autopilot flashing, or compass/telemetry testing under any circumstances.
Authorized Outdoor Flight Hold Point
Do not conduct outdoor flight tests without confirming legal DGCA permissions, green zone airspace clearance, and qualified pilot supervision.
Quality Gate Acceptance Evidence (G0 – G8)
| Gate | Testing Scope | Mandatory Acceptance Evidence |
|---|---|---|
| G0 Incoming | Components, serials, physical damage, datasheets | Incoming inspection sheet signed; nonconforming parts quarantined |
| G1 Mechanical | Frame alignment, landing gear, torque records | Checklist & calibrated torque log verified per drawing |
| G2 Electrical | Continuity, polarity, insulation, connector retention | Two-person independent polarity sign-off before energizing |
| G3 Avionics | Sensor orientation, GNSS lock, failsafes, telemetry | Configuration version recorded; parameter backup XML saved |
| G4 Spray | Fluid leak test, flow rate, nozzle consistency, pump current | Zero pressure drop over 15 mins at 3 bar using safe test fluid |
| G5 Battery/Thermal | Battery internal resistance, thermal imaging under discharge | Peak temperature <65°C under continuous high-current load |
| G6 Ground Validation | Dynamic vibration analysis, center of gravity, balance | Vibration amplitude <0.2g; center of gravity within ±3mm |
| G7 Flight Testing | Controlled outdoor hover, AB route accuracy, RTH failsafe | Approved test plan, flight logs recorded, safety observer present |
| G8 Release Review | BOM reconciliation, user manual, DGCA compliance file | Go/no-go review signed by project owner & engineering lead |