How can we match the test database plan to the production database without using Plan Stability?
Plan Stability is the exact tool for the job. I'm not sure why you want to perform the job and not use the tool that was specifically developed for this exact purpose.
That being said, you can use the DBMS_STATS package to export the object statistics. Then transfer those statistics...
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to the production database and import there, again using DBMS_STATS. Finally, use DBMS_STATS to lock down the statistics so that they cannot be changed.