🏗️ Progressive Build vs Stall Build: Choosing the Right Strategy for Custom Equipment Manufacturing
In custom OEM manufacturing—especially in industries like road construction equipment—the way you organize your production process can significantly influence your efficiency, quality, and scalability. Two widely used strategies are the Progressive Build and the Stall Build.
Each method has its strengths and is suited to different production environments. To better understand these approaches, let’s explore how they apply to real-world examples—such as aircraft manufacturing and asphalt distributor assembly—and how they shape the way we plan and manage production.
✈️ Stall Build: A Strategy for Complex, Custom Machines
In a Stall Build, the product remains stationary in a dedicated bay or stall, while technicians and tools move around it. This method is ideal for complex, high-value, or highly customized machines and less space.
🧩 Key Characteristics:
The product stays in one location throughout the build
Multiple teams can work in parallel
Offers high flexibility for design changes or customer-specific configurations
Best suited for low-volume, high-complexity production, space constraint
Often chosen due to space constraints, especially in facilities where linear flow lines are not feasible
🛠️ Example: Aircraft Manufacturing
Aircraft like the Boeing 787 or Airbus A350 are assembled using stall builds. Each aircraft is parked in a large hangar, and teams install systems such as fuselage sections, wings, avionics, hydraulics, and interiors—all in the same location. This approach allows for precision, customization, and strict quality control.
🛠️ Application in Asphalt Distributors
Stall builds are also used in asphalt distributor manufacturing, especially for:
Prototypes or first builds
Custom configurations
Projects with frequent design changes
Facilities with limited floor space, where setting up a progressive line is not practical
The truck remains in a single bay while teams install the tank, burner, hydraulics, spray bar, and control systems in sequence or in parallel.
🚛 Progressive Build: A Strategy for Scalable, Repeatable Production
In a Progressive Build, the product moves through a series of workstations, with each station responsible for a specific set of tasks. This method is ideal for repeatable builds and higher production volumes.
🧩 Key Characteristics:
The product moves from one station to the next.
Each station performs a defined scope of work.
Materials and tools are pre-positioned at each station.
Best suited for standardized, scalable production.
🛠️ Application in Asphalt Distributors
When asphalt distributors are built in larger volumes or with standardized configurations, a progressive build approach is often adopted. For example:
Station 1: Mount the tank and brackets
Station 2: Install the burner and fuel system
Station 3: Fit hydraulic and spray systems
Station 4: Electrical wiring and control panel
Station 5: Final inspection and testing
🔄 Build Strategy Shapes the Way You Plan
One of the most important but often overlooked aspects of choosing a build strategy is how it influences your planning systems—especially your Manufacturing Bill of Materials (MBOM).
The MBOM is not just a list of parts—it is a direct byproduct of your build strategy.
In a Progressive Build:
The MBOM is modular and station-specific.
It includes routing information, kitting instructions, and sequenced subassemblies.
It supports lean manufacturing and just-in-time material flow.
In a Stall Build:
The MBOM is consolidated and system-oriented.
It supports parallel operations and flexible sequencing.
It allows for on-the-fly adjustments and custom configurations.
Even the structure of the EBOM (Engineering Bill of Materials) may be influenced by the build method, especially when design teams collaborate closely with manufacturing to optimize for buildability.
⚖️ Comparing the Two Strategies
Feature
Stall Build (Aircraft, Custom Distributors)
Progressive Build (Truck-Based Distributors)
Product Movement
Stationary
Moves through stations
Best For
Complex, custom builds
Repeatable, scalable builds
Labor Skill
Multi-skilled teams
Specialized per station
Flexibility
High
Moderate
Space Requirement
Large bays
Linear flow layout
Cycle Time
Variable
Predictable
Change Adaptability
Excellent
Limited
Scalability
Challenging
Easier to scale
MBOM Structure
System-based, flexible
Modular, sequenced, station-specific
🧭 Final Thoughts
There’s no one-size-fits-all approach. The Stall Build offers flexibility and control for complex, high-value machines like aircraft or custom asphalt distributors. The Progressive Build offers speed and efficiency for repeatable, truck-based equipment.
And behind every build strategy is a planning system that must adapt—because your MBOM is not just a document, it’s a reflection of how you build.
Many manufacturers adopt a hybrid approach—starting with stall builds during early development and transitioning to progressive builds as the product matures and demand increases.
Progressive Build vs Stall Build
🏗️ Progressive Build vs Stall Build: Choosing the Right Strategy for Custom Equipment Manufacturing
In custom OEM manufacturing—especially in industries like road construction equipment—the way you organize your production process can significantly influence your efficiency, quality, and scalability. Two widely used strategies are the Progressive Build and the Stall Build.
Each method has its strengths and is suited to different production environments. To better understand these approaches, let’s explore how they apply to real-world examples—such as aircraft manufacturing and asphalt distributor assembly—and how they shape the way we plan and manage production.
✈️ Stall Build: A Strategy for Complex, Custom Machines
In a Stall Build, the product remains stationary in a dedicated bay or stall, while technicians and tools move around it. This method is ideal for complex, high-value, or highly customized machines and less space.
🧩 Key Characteristics:
🛠️ Example: Aircraft Manufacturing
Aircraft like the Boeing 787 or Airbus A350 are assembled using stall builds. Each aircraft is parked in a large hangar, and teams install systems such as fuselage sections, wings, avionics, hydraulics, and interiors—all in the same location. This approach allows for precision, customization, and strict quality control.
🛠️ Application in Asphalt Distributors
Stall builds are also used in asphalt distributor manufacturing, especially for:
The truck remains in a single bay while teams install the tank, burner, hydraulics, spray bar, and control systems in sequence or in parallel.
🚛 Progressive Build: A Strategy for Scalable, Repeatable Production
In a Progressive Build, the product moves through a series of workstations, with each station responsible for a specific set of tasks. This method is ideal for repeatable builds and higher production volumes.
🧩 Key Characteristics:
🛠️ Application in Asphalt Distributors
When asphalt distributors are built in larger volumes or with standardized configurations, a progressive build approach is often adopted. For example:
🔄 Build Strategy Shapes the Way You Plan
One of the most important but often overlooked aspects of choosing a build strategy is how it influences your planning systems—especially your Manufacturing Bill of Materials (MBOM).
In a Progressive Build:
In a Stall Build:
Even the structure of the EBOM (Engineering Bill of Materials) may be influenced by the build method, especially when design teams collaborate closely with manufacturing to optimize for buildability.
⚖️ Comparing the Two Strategies
🧭 Final Thoughts
There’s no one-size-fits-all approach. The Stall Build offers flexibility and control for complex, high-value machines like aircraft or custom asphalt distributors. The Progressive Build offers speed and efficiency for repeatable, truck-based equipment.
Many manufacturers adopt a hybrid approach—starting with stall builds during early development and transitioning to progressive builds as the product matures and demand increases.