Prototype logistics

Prototype logistics is a central component of the early development and testing phases of new products and plays a key role between Research & Development, prototype and test builds, and subsequent series production processes. Its primary objective is the flexible, demand-oriented, and secure supply of all functions involved with prototype and test parts – often under special conditions such as high component value, dynamic requirements, and strict confidentiality.

Prototype logistics primarily covers the planning, control, and execution of all logistics processes related to prototypes: from procurement and specialized packaging to transportation, temporary storage, and on-time provision for testing activities or pilot assemblies. Particular emphasis is placed on sensitive handling, end-to-end traceability, and the ability to reliably respond to frequent changes and varying quantities.

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• Different types of prototypes – frequent changes, irregular delivery cycles, varying delivery quantities
• Specialized packaging, sensitive materials, and potential Just-in-Time or Just-in-Sequence requirements
• Need for flexible logistics processes, potentially integrated into production or manufacturing planning
• Demand-oriented material provision without fixed cycles and without standardized line-side equipment
• Demand-specific picking and kitting of components for supply processes
• High requirements for security, confidentiality, and documentation (e.g. NDAs, secure handling)

• Requirements analysis: classification of parts, value, and security or protection needs
• Development of customized logistics and packaging concepts (including packaging logistics, secure transport, handling, and documentation)
• Planning of warehousing or interim storage solutions, e.g. temporary buffer storage, consolidated shipments, and special handling concepts
• Integration into the supply chain and production network: handover to production, testing, and series ramp-up
• Support throughout the prototype phase: regular reviews, adaptations to changes, and full traceability (Track & Trace)

• Risk minimization: protection against damage, loss, and confidentiality breaches
• Cost and resource efficiency through optimized processes, e.g. consolidated transports and suitable storage strategies
• Process leveling of manufacturing steps and definition of decoupling quantities
• Transparency and control through robust processes and documentation, even under changing requirements
• Faster series ramp-up through a smooth transition from prototype to series production
• Combination of logistics, supply chain management, production, and process consulting – ideal for complex projects such as prototype logistics
• Neutral, manufacturer-independent consulting and solution design – flexible adaptation to customer-specific requirements and seamless transition from consulting to implemented solutions
• Strong practical focus and implementation orientation – not just concepts, but active support during process integration and, if desired, during live operations