Assembly and logistics: planning for them early
Assembly and logistics are often left until the end of a project. Here’s why planning them early saves money and avoids delays.
When a product is being designed, the focus is naturally on what it does and how it looks. Assembly and logistics can seem like problems for later. But decisions made early in development have a big influence on both, and leaving them too long is a common and costly mistake.
Assembly: what to think about early
- Where will it be assembled? At the main factory, at a specialist assembly site, or in a different country from the components? Each has different cost and quality implications.
- How will it be assembled? By hand, semi-automated, or on a line? The design should suit the method.
- What tools and fixtures are needed? Jigs and test rigs need to be designed and built, and take time.
- How will it be tested? End-of-line checks should be defined before production, not invented during it.
- What skill is required? A design that needs specialist skill at every step is harder to scale.
Logistics: what to think about early
- Packaging. It needs to protect the product, suit the shipping method, and be cost-effective. Its size affects how many units fit in a container or on a pallet, and so freight cost per unit.
- Transport. Air, sea, road or a combination? Each has different cost, speed and risk.
- Regulations and customs. Product classification, duties, labelling and documentation vary by market.
- Warehousing and distribution. Where will stock be held and how will orders be fulfilled?
- Returns and repairs. Have a plan for what happens when things come back.
Why early planning pays
Small design changes can have a large effect. A slightly smaller pack size could reduce freight costs noticeably. A change to a fixing might halve assembly time. Either is straightforward on screen and difficult once tooling has been made.
We consider assembly and logistics as part of development, not as an afterthought, and we help clients plan for both from the beginning.
If you’re developing a product and want to be sure these areas are covered, talk to us.