Automation of work preparation in production
Executive Summary - Automation of work preparation at a glance
- Strategic importance: Automated work preparation is becoming a lever for stable, resilient and future-proof production processes - especially in variant-rich or time-critical production environments.
- Operational benefits: Information flows together consistently, work plans are derived automatically, errors are reduced and throughput times are shortened - independent of individual knowledge carriers. At the same time, a basis for AI is created.
- Quality & transparency: Consistent parts lists, clean resource planning and traceable process steps increase stability and confidence in planning & production.
- Relief for employees: Manual tasks are eliminated, coordination efforts are reduced and teams can concentrate on value-adding work again.
- Success factors: Data harmonization, clear interfaces, standardized processes and the early involvement of specialist departments ensure sustainable effectiveness.
Challenges in work preparation - why the pressure for automation is increasing
Work preparation remains a bottleneck in many production companies because key steps are still highly manual, time-consuming and error-prone. Before parts lists or resources can even be considered, the product specified by the customer must first be validated and converted into a technically buildable variant. Sales, development, production and logistics must work closely together to achieve this, as factors such as configuration rules, purchased part validities or location decisions influence whether a product variant can be built completely and correctly.
Only then does the real work begin: Information from ERP, PLM, CAD, drawings, work plans or tool data must be painstakingly compiled, checked and re-translated for the order. The BOM resolution is often based on a 150% eBoM, which is manually broken down and then supplemented with production-related, logistical and sometimes site-specific parameters. In order to create a truly usable “100% manufacturing BoM” or a reliable bill of process (BOP) for the respective order, pre-assemblies, sub-components and production steps must be precisely defined and distributed to the appropriate plants or lines.
The more varied the products, the more locations involved and the more inconsistent the documentation statuses, the more complex and risky this AV process becomes. Late order or product changes can often only be implemented with massive additional effort or not at all. And because many steps exist exclusively in the minds of a small number of know-how carriers, a dangerous dependency arises – with all the risks associated with growth, fluctuation or increasing requirements. The result is unstable processes, unnecessary waiting times and operational uncertainty along the entire value chain.
Consequences - what becomes visible in production & work preparation
- High time losses due to manual information search, data enrichment and translation
- Incorrect parts lists (BOP/mBOM) and unstable work plans that generate rework, additional work and coordination requirements
- Delays in production due to missing material, incorrectly booked resources or tool conflicts
- Dependence on individual knowledge carriers, which means that processes can come to a standstill when individual people leave
Your contacts for automation in work preparation
Our solution - How automated work preparation transforms processes
For the first time, our solution combines all technical, logistical and production-related work preparation parameters in one central location. It generates modular intermediate products and links them with order-specific material, tools, machines and personnel – automatically, consistently and traceably. Using standardized workflows, orders are automatically resolved via direct interfaces (ERP, MES, PLM) and translated into complete, quality-assured work plans.
The result is a standardized, robust and scalable AV process that minimizes errors, reduces coordination effort and noticeably cuts throughput times. Knowledge carriers are relieved as their know-how is documented in advance and used systematically. Companies gain stability, quality and speed – without having to replace their existing systems.
The benefits at a glance
- Noticeably shorter throughput times thanks to automated work plan and parts list creation
- Fewer errors, rework and coordination - more operational stability
- Relief for key personnel & reduced knowledge dependency
- Better material, tool and machine availability
- Higher data quality and transparent, reproducible processes
- Enabling the use of AI
In the first step, we analyze the business-relevant capabilities relating to product documentation and order resolution and define a clear, sustainable target picture based on this. We break down these capabilities into specific areas of responsibility and assign them to the respective organizational units. This creates a structured scope that enables teams to work on topics in a focused, parallel and targeted manner. This common framework creates orientation, reduces complexity and forms the basis for a clean, scalable AV transformation.
Based on the defined capabilities, we translate requirements into processes and system logic. To do this, we record the existing processes in detail, document data sources and analyze dependencies – not only within AV, but also in upstream and downstream processes such as assembly, logistics or change management. We then harmonize process and system flows, identify potential for optimisation and design a scalable target architecture for digital AV. The result is an end-to-end process and system design that reduces media disruptions and creates a clean database.
In the implementation phase, we implement the harmonized data flows, interfaces, rules and process logics in the existing system landscape. We integrate ERP, PLM and MES systems so that they work consistently with each other and enable seamless, automated order resolution. This results in a robust, stable and reproducible AV process that is viable for both variant production and series processes.
Finally, we ensure that teams master the new AV landscape with confidence: We train roles, communicate standards, support pilots and ensure clear governance. Practice-oriented enablement and targeted support during the transition ensure a high level of acceptance throughout the entire production environment. The new AV is not only introduced technically, but also anchored organizationally – and thus effective in the long term.
Why Ventum Consulting is the right partner for automation in work preparation
Over 20 years of experience
We have in-depth expertise in production, engineering, data and process worlds - and are familiar with the real challenges of work preparation.
Holistic approach
We don't think of work preparation in isolation, but integrated into ERP, PLM, MES, logistics and HR processes - for genuine end-to-end stability.
Practice-oriented implementation
We don't deliver theory, but implementable solutions that work in real production environments and achieve measurable results.
Scalable standards
We create systems that can grow stably - even with an explosion of variants, higher cycle times or increasing complexity.
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- Strategic: Automated AV processes, digital parts lists, workflow-based work plans
- Secure: data and process harmonization, integrated interfaces, transparent rules
- Proven in practice: Experience in manufacturing, mechanical engineering, variant production & series production
- Measurable: focus on throughput time, error rate, material availability & stability
- Holistic: people, technology, data, governance & processes
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FAQ - Automation of work preparation
Companies regularly report a drastic reduction in manual activities, as information no longer has to be laboriously collected. Many intermediate steps run automatically in the background. The time saved can flow directly into production, quality inspection or process optimization.
The processes are based on validated rules, consistent data models and clear parameters. Errors are detected much earlier as systems check plausibility and issue warnings. This significantly increases process reliability compared to purely manual processes.
Thanks to systematic documentation and automated derivation, central information is stored in a structured manner. Know-how remains available within the company and processes become less dependent on individual people. This increases the resilience of the entire production organization.
Existing systems are seamlessly integrated via APIs, defined interfaces and data harmonization. We ensure that relevant information is retrieved where it is generated. The transition takes place gradually – without operational risks.
Most companies achieve the first measurable increases in efficiency after just a few weeks. The reduction in errors and less rework also increases indirect savings. The ROI is often in the region of a few months.