Smart Material Provisioning

This is exactly what a study by the Institute for Integrated Production Hanover (IPH) confirms. Simulation-based planning not only reduces lead time but also improves space utilization and increases process reliability. Even though the study focuses on the entire material flow, many of the findings can be directly applied to smart material provisioning. This concept enables targeted placement, reduces relocations, and significantly improves coordination between logistics and assembly.

Nevertheless, in many production areas, materials are still stored wherever there’s leftover space. Those who know the processes try to place the materials as cleverly as possible and keep the paths short with a bit of experience. As long as the product portfolio remains manageable, this approach can work surprisingly well.

However, with increasing product variety, shorter cycle times, and rising efficiency pressures, this principle reaches its limits. Materials are provided incorrectly or too late, walking distances become unnecessarily long, and output suffers as a result. This leads to more effort, less transparency, and increased error rates.

What does “smart” mean in material provisioning?

Smart material provisioning isn’t a rigid process but a flexible system. It’s not just about supplying parts, but about a structured plan that can be adapted at any time. Instead of providing material according to fixed patterns, it’s planned based on actual needs. Factors such as part type, cycle time, available space, and delivery frequency all play a role in decision-making. Digital planning makes these relationships visible and supports planners in organizing the supply optimally. This creates a functional interplay between logistics and assembly.

Where smart concepts have the greatest impact

The benefits of smart provisioning become especially clear in areas with high product variety. Wherever processes and quantities change constantly, rigid concepts quickly fail. And when space on the production line becomes scarce, new ideas are needed.

Digital planning enables solutions that can be tailored to individual needs. For example, mixed concepts combining supermarket, JIT, or JIS provisioning adapted to the part type. Even the positioning of storage areas can be designed to save space and shorten walking distances.
Companies with multiple assembly lines benefit in particular. When supply is centrally planned and visually simulated, processes can be stabilized and resources better utilized.

Implementing smart material provisioning

In the past, material provisioning was often organized based on experience. Planners worked with simple drawings or spreadsheets and distributed materials based on gut feeling. Changes in processes often meant making spontaneous decisions on-site.
Today, a different approach is in focus. Smart material provisioning relies on digital planning tools and simulation. Even during preparation, scenarios can be compared: Where are the bottlenecks? Which materials change when variants change? Which concept fits the existing layout?
Software solutions like ipolog realistically map these questions. They combine information about spaces, products, cycle times, and transports into one continuous model. This way, planners can see whether the provisioning concept is viable and make targeted adjustments.

Planning from the workstation perspective

An often underestimated lever lies in perspective. In many companies, material provisioning planning begins with the question of where there’s still space available. The focus is thus on the space, not the work process. However, the key is to plan from the workstation perspective. The crucial question is: “How can the employee best access the material?”
ipolog makes this possible: The software shows how the position of the material affects reach paths, ergonomics, and cycle time. This not only shortens paths but also avoids search times and unnecessary movements. It reduces error rates and eases the workload of the team. Workplace-focused planning brings measurable advantages.

This change isn’t just technical—it also affects the organization. Departments work more closely together, decisions are transparently documented, and production starts become more structured. Smart provisioning brings order to an area that was often improvised in the past.

Advantages of smart material provisioning

When planning is data-driven, it has a significant impact on daily work in assembly. Storage areas can be used more purposefully. This creates more structure and reduces disruptions.
Walking distances become shorter because materials are placed exactly where they’re needed. Clear processes and transparent storage concepts reduce misunderstandings. At the same time, the quality of supply improves because last-minute adjustments are less frequent.
Logistics staff are relieved, and production runs more smoothly. Especially in times of skilled labor shortages and increasingly complex manufacturing processes, this is a crucial advantage.

Example from practice

An international company with complex assembly and production logistics faced the challenge of supplying several lines efficiently with limited space. The provisioning was not designed for the high product variety. There were frequent bottlenecks, last-minute relocations, and increased personnel effort.
The company implemented a digital planning tool that visually depicted the entire material provisioning process and allowed for simulation-based validation. Different concepts—such as sequenced deliveries, buffer optimization, and space-saving storage strategies—were compared and evaluated.
After implementation, the average walking distance per assembly order was reduced by around 18 percent. The required storage space in the provisioning area decreased significantly. At the same time, on-time delivery improved because missing parts became less common.
Digital planning not only led to more efficient processes but also to higher satisfaction within the team. Daily work became noticeably clearer and more structured.

Conclusion