11.11.2025
How to master the complexity of configure-to-order (CTO+):
Industrial manufacturing faces the constant challenge of delivering complex, customized products efficiently and without errors. The configure-to-order (CTO) scenario, in which products are only configured and manufactured after the customer's order has been received, is a decisive competitive advantage, but it also carries considerable risks. Without a comprehensive digital strategy, manual processes, data silos, and a lack of consistency quickly lead to errors, delays, and unnecessarily high costs.
For companies that want to take their customer-specific manufacturing processes to the next level - known as CTO+ - far-reaching automation and standardization are essential.
The three pillars of CTO+ excellence
To successfully manage the complexity of the CTO+ lifecycle, companies must establish three strategic pillars that support the entire process from initial inquiry to delivery:
1. Synchronization of the entire CTO+ lifecycle
The traditional process is often fragmented: sales, engineering, production, and service work with different data and systems. This results in media breaks and costly errors when transitioning from one phase to the next.
The key to efficiency lies in the end-to-end connection and synchronization of product and process data throughout the entire CTO+ lifecycle. This includes the seamless transfer of information from the quotation phase through detailed technical configuration and production planning to delivery and service. This is the only way to ensure that the final production is precisely tailored to the customer's requirements and the original calculation.
2. A central product data model for agility and consistency
Managing multiple ordering and manufacturing models for customer-specific products is virtually impossible without central control. A central product data model serves as a single source of truth. It harmonizes all relevant information and ensures a consistent database across all departments.
This central database enables greater agility in responding to customer requirements and ensures the consistency of product information. This is the basis for automated processes and faster decision-making.
3. Modularization to increase reuse and resilience
The constant development of new, customer-specific parts drives up costs and reduces the resilience of the supply chain. The solution lies in modularization. By breaking down complex products into standardized, reusable modules, the variety of parts can be drastically reduced.
Modularization leads to significant gains in
The guide through complexity: The Interactive Value Journey
The theoretical implementation of these pillars is one thing—their practical application is another. This is precisely where the Interactive Value Journey (IVJ) comes in. It serves as a structured guide that breaks down the entire CTO+ process into logical, comprehensible steps.
The IVJ highlights the critical phases that every company goes through in the CTO+ environment:
- Inquiry-to-Quote: How to create accurate and fast quotes for standard and customized products.
- Order Configuration and Engineering: Technical order planning and management of detailed, customized designs.
- Production Engineering and Planning: Automated handover to manufacturing structures and detailed project and cost planning.
- Order Fulfillment and Delivery: From production execution and progress monitoring to final cost control and delivery.
Each phase shows how a higher level of automation and efficiency can be achieved through the use of modern digital solutions.
Start your transformation:
Would you like to see in detail how your company can master the challenges of Configure-to-Order(+) and benefit from harmonized, end-to-end manufacturing?
Click here to start the Interactive Value Journey and explore your individual path to CTO+ excellence:
To the Interactive Value Journey
Use this interactive tool to identify the potential in your own company and understand the added value of an integrated process landscape.
