Procurement Glossary
Zero series procurement: definition, methods and strategic importance
November 19, 2025
Pilot series procurement refers to the procurement of components and materials for the production of prototypes and pre-series products before the actual start of series production. This phase is crucial for the validation of product designs, supplier capabilities and production processes. Find out below what pilot series procurement involves, which methods are used and how you can successfully minimize risks.
Key Facts
- Pilot series procurement takes place before the regular start of series production to validate products and processes
- Smaller quantities and higher unit costs characterize this procurement phase
- Close cooperation with suppliers is necessary for quality assurance and process optimization
- Focus on early identification of risks and optimization potential
- Transition to series procurement requires careful planning and coordination
Contents
Definition: Zero series procurement
Pilot series procurement comprises all activities relating to the procurement of materials, components and services for the manufacture of prototypes and pre-production samples prior to the regular start of production.
Core elements of pilot series procurement
Zero-series procurement is characterized by specific features that distinguish it from regular series procurement:
- Small quantities with correspondingly higher purchase prices
- Flexible delivery dates to support development cycles
- Intensive quality checks and documentation requirements
- Close coordination between development, production and suppliers
Zero series procurement vs. series procurement
In contrast to series procurement, pilot series procurement focuses on learning and validation rather than cost optimization. While established processes are used for small series production, the focus is on process development for pilot series.
Importance of pilot series procurement in Procurement
For Strategic Procurement , pilot series procurement forms the basis for successful supplier relationships and cost structures in subsequent series production. The knowledge gained flows directly into the series release processes.
Methods and procedures
Successful pilot series procurement requires structured procedures and proven methods for risk minimization and quality assurance.
Supplier selection and qualification
The selection of suitable suppliers for the pilot series is based on specific criteria that go beyond the regular requirements. Suppliers must demonstrate flexibility, development expertise and the ability to react quickly.
- Evaluation of development and prototyping capabilities
- Testing of quality assurance systems for small batch sizes
- Analysis of capacities for short-term changes
Procurement planning and control
The planning of pilot series procurement requires close coordination with product development and ramp-up management. Special attention is paid to the synchronization of material availability and development progress.
Quality management and documentation
Comprehensive documentation of all procurement activities and quality checks forms the basis for the subsequent start of series production. Every deviation and optimization is systematically recorded and evaluated.
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Key figures for controlling zero-series procurements
Specific key figures enable the effective control and evaluation of pilot series procurement.
Quality indicators
Quality performance in the pilot series is crucial for the subsequent success of series production. Key performance indicators include the first-pass yield rate and the number of quality deviations per supplier.
- Scrap rate as a percentage of delivered parts
- Number of reworks per 1,000 parts
- Supplier quality index based on error categories
Adherence to deadlines and delivery dates
On-time deliveries are particularly critical in pilot production, as delays can affect the entire development process. The on-time delivery rate should be at least 95%.
Cost transparency and development
Tracking costs in the pilot series forms the basis for realistic series calculations. Particular attention is paid to the development of unit costs and the transition to prototype procurement.
Risks, dependencies and countermeasures
Zero-series procurement involves specific risks that can be minimized by taking appropriate measures.
Supplier risks and quality uncertainties
Untested suppliers and processes can lead to quality problems and delays. Limited experience with new products increases uncertainty considerably.
- Implementation of backup suppliers for critical components
- Intensive quality audits and process validations
- Continuous monitoring of supplier performance
Cost risks and budget overruns
Higher unit costs and unforeseen changes can lead to significant budget deviations. The make-or-buy decision is often re-evaluated in this phase.
Schedule risks and project dependencies
Delays in the pilot series can jeopardize the entire product launch. Dependencies between different components and suppliers are particularly critical and require careful ramp-down planning.
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Practical example
A car manufacturer is planning the pilot series procurement for a new electric vehicle. Three potential suppliers are qualified for the battery modules and 50 prototype units are ordered for each. At the same time, test equipment and testing devices are procured. The intensive quality testing reveals optimization potential in the cell configuration, which is implemented before the start of series production. The knowledge gained is incorporated into the final supplier selection and contract design.
- Early identification of quality risks through intensive testing
- Cost optimization by comparing different supplier approaches
- Establishing supplier relationships before the critical start of series production
Trends & developments around zero series procurement
Zero-series procurement is subject to continuous change due to technological developments and changing market requirements.
Digitalization and AI integration
Artificial intelligence is revolutionizing pilot series procurement through predictive analytics and automated supplier evaluation. AI systems analyze historical data and predict risks in the early project phases.
- Automated supplier pre-selection based on project requirements
- Predictive quality management for early fault detection
- Intelligent inventory optimization for prototype materials
Agile procurement methods
Agile approaches are becoming increasingly important in pilot series procurement in order to react flexibly to development changes. Joint development manufacturing is increasingly being used as a strategic approach.
Sustainability and circular economy
Sustainability aspects are already incorporated into pilot series procurement in order to avoid subsequent conversions. Suppliers are checked for environmental standards and circular economy principles at an early stage.
Conclusion
Pilot series procurement forms the foundation for successful product launches and sustainable supplier relationships. Investing in high-quality pilot series pays off through risk minimization and process optimization in subsequent series production. Modern technologies such as AI and agile methods are revolutionizing traditional approaches. Companies that use pilot series procurement strategically create decisive competitive advantages through higher product quality and faster time to market.
FAQ
What is the difference between zero-series procurement and regular procurement?
Pilot series procurement focuses on small quantities for prototypes and validation, while regular procurement is geared towards cost optimization and large volumes. The quality requirements and documentation obligations are significantly higher in the pilot series, as knowledge must be gained for later series production.
How long does it typically take to procure a pilot series?
The duration varies between 3-12 months depending on product complexity and industry. The decisive factors are the number of iteration loops, the availability of special materials and the coordination between development and suppliers. Automotive projects often take 6-9 months, while electronic products can be realized more quickly.
What costs are incurred in pilot series procurement?
The unit costs are typically 200-500% higher than the subsequent series prices due to small batch sizes and special requirements. Additional costs arise from intensive quality checks, documentation and possible reworking. This investment pays for itself by minimizing risk and optimizing subsequent series production.
How is quality ensured in the pilot series?
Quality assurance is achieved through multi-stage inspection concepts, intensive supplier audits and continuous process monitoring. Each part is individually tested and documented. Statistical evaluations help to identify trends and optimization potential for subsequent series production.
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