Partner with a fitness expert who will write the script for the DVD. The script will not be a traditional film script but rather the exercise program of the DVD. The expert doesn't have to be the instructor who will appear in the DVD.
Write the script and storyboard it. The entire production -- from the exercise program to the filming directions, including specific shots -- will need to be prepared and refined before taping starts. This is the road map for the production team.
Cast the performers. Most fitness DVDs have a lead trainer and two or more backup trainers who follow along. Select people with good looks and great physiques -- after all, this is what the people watching the DVD will look like when they are done, right? Fitness trainers are best for the roles, as they know the proper form and execution of the exercises.
Select sites for filming. These should be warm and inviting. Typical sites are a clean, well-lit gym, a beach, a park or a fitness studio. They should be able to accommodate the production equipment and staff.
Rehearse the performance. The lead performer will do most of the talking. The most important thing the performers need to learn is the correct movements for the exercises. The production staff should also prepare and practice shots, then review them to see which ones work best. Once everybody has the entire program down, filming can begin.
Set up the lighting. Use several tungsten lights of at least 500 watts to make sure the set is well lit. Two to four lights should be enough to eliminate most shadows and keep the performers clear and visible.
Use a boom mic to record the sound.
Shoot the DVD. One or two HD cameras will be needed. The cameras should shoot in 1080P.
Edit the DVD. Several video editing programs are available. They include Adobe Premiere Pro, Adobe After Effects, Sony Vegas and Apple's Final Cut.