Procurement Glossary
Series release process: Structured release for series production
November 19, 2025
The series release process is a critical milestone in product development that regulates the transition from the prototype phase to series production. This structured process ensures that all technical, qualitative and economic requirements are met before mass production begins. Find out below what constitutes the series release process, which methods are used and how you can successfully minimize risks.
Key Facts
- Formal approval process between development and series production with defined quality criteria
- Includes technical validation, process stability and supplier qualification
- Reduces series start-up risks and prevents costly reworking
- Involves all relevant stakeholders from development to procurement
- Documents all release criteria and test results for traceability
Contents
Definition: Series release process - meaning and objectives
The series release process defines the systematic transition from the development phase to series production of a product.
Core elements of the series release process
The process comprises several critical components that together ensure series maturity:
- Technical validation of all product specifications
- Qualification of production processes and suppliers
- Proof of process stability over defined quantities
- Release of production tools and equipment
Series release vs. prototype release
While prototype procurement provides individual functional samples for testing, the series release process validates the entire production and supply chain. The start of series production only follows after successful approval.
Importance in Procurement
For procurement, the series release marks the starting point for volume contracts and long-term supply relationships. It forms the basis for ramp-up management and strategic supplier partnerships.
Methods and procedures
Structured methods ensure systematic and traceable series release.
Stage-gate procedure
The multi-stage release process defines clear milestones with specific criteria. Each stage requires defined deliverables and proof of quality before the next phase can begin. Typical gates include design freeze, pilot run and final series release.
Supplier qualification
Feasibility reviews are used to systematically evaluate and approve all series suppliers. This validates production capacities, quality systems and delivery capability. Particular attention is paid to tool approval for critical production tools.
Documentation and tracking
All approval decisions are systematically documented and stored in a traceable manner. This includes test protocols, supplier evaluations and risk analyses for subsequent audits and continuous improvements.
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Key figures for controlling series release processes
Measurable key figures enable objective evaluation and continuous optimization of the approval process.
Lead time key figures
The total lead time from the start of release to final approval is a key performance indicator. Typical target values are between 8-16 weeks depending on product complexity. Sub-indicators for each approval stage identify bottlenecks and optimization potential in the process.
Quality indicators
First-pass yield measures the proportion of successful initial approvals without rework. Target values above 85% indicate robust preliminary processes. The number of critical findings per release and their resolution time are further important quality indicators for process maturity.
Cost and efficiency KPIs
Release costs per project and resource expenditure per release stage enable efficiency comparisons. The return on investment from avoided serial problems justifies investments in thorough approval processes and shows the value contribution of systematic validation.
Risk factors and controls in series release processes
Systematic risk identification and control are essential for successful series releases.
Technical risks
Incomplete product validation can lead to costly rework in series production. Critical risk factors include insufficient test coverage, lack of long-term testing and unvalidated manufacturing processes. Robust test plans and safe launch strategies minimize these risks.
Supplier risks
Unqualified or unstable suppliers significantly jeopardize the start of series production. Risks are minimized through multi-stage supplier evaluation, backup strategies and continuous monitoring. Outsourcing potential analyses help with strategic supplier selection.
Process and time risks
Delays in the approval process can jeopardize market launch dates and cost competitive advantages. Effective controls include realistic scheduling, parallelization of activities and proactive stakeholder management to accelerate critical decisions.
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Practical example
An automotive supplier implements a structured series release process for a new brake system. After successful pilot series procurement, the product goes through three release stages: Design validation, process qualification and final series release. Each stage requires specific evidence such as material tests, production runs and supplier certifications. The process takes 12 weeks and involves development, quality, Procurement and production.
- Week 1-4: Technical validation and material tests
- Week 5-8: Supplier qualification and process validation
- Weeks 9-12: Final approval and preparation for series production start-up
Current developments and effects
Modern technologies and changing market requirements are shaping the evolution of the series release process.
Digitalization and AI integration
Artificial intelligence is revolutionizing data analysis in approval processes through automated quality assessments and predictive analytics. Machine learning algorithms identify patterns in production data and predict potential series start-up problems at an early stage.
Agile release methods
Shorter product life cycles require more flexible release processes with iterative approaches. Parallel validation steps and continuous risk assessment accelerate time-to-market without any loss of quality. Ramp-up strategies are becoming increasingly modular.
Sustainability integration
Environmental and social criteria are systematically integrated into approval decisions. In addition to technical standards, suppliers must also meet sustainability standards, which introduces new evaluation dimensions into the approval process.
Conclusion
The series release process is a critical success factor for the market launch of new products and forms the basis for stable series production. Structured methods, clear criteria and systematic risk controls minimize start-up problems and ensure quality. Modern digitalization approaches and AI integration offer new opportunities for process optimization and increased efficiency. Investments in robust approval processes pay off in the long term by avoiding series production problems and accelerating market launches.
FAQ
What is the difference between series release and prototype release?
The series release validates the entire production and supply chain for mass production, while prototype releases only concern individual functional samples for testing. Series releases require comprehensive supplier qualification, process stability and long-term tests, which are not necessary for prototypes.
Which stakeholders are involved in the approval process?
Typical stakeholders include product development, quality management, Procurement, production and suppliers. Depending on the industry, regulatory affairs, sales and external testing organizations may also be involved. Clear roles and responsibilities are essential for efficient decision-making.
How long does a typical series release process take?
The duration varies greatly depending on product complexity and industry. Simple products require 6-10 weeks, complex systems can take 16-24 weeks. Parallelization of activities and digital tools can significantly reduce lead times without sacrificing quality.
What costs are incurred due to insufficient series release?
Inadequate approval processes can lead to considerable follow-up costs: Production downtime, rework, supplier changes and reputational damage. Studies show that error costs in series production are 10-100 times higher than in the development phase, which justifies robust approval processes.
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