Industry
Security Technology
Project Duration
18 Months
Quantity
10.000+
Locations
Germany & Asia
The Assignment
THE INITIAL SITUATION
A seemingly impossible task: A completely new device for capturing biometric data must be developed, produced, and delivered in five-figure quantities within just 18 months.
What makes this project a challenge?
Starting Point
At the beginning of the project, an initial concept, preliminary technical considerations, and an early prototype demonstrating the system’s basic idea are available.
Extreme Time Pressure
From the initial creation of a detailed and security concept to the development of pre-series devices and widespread rollout, only eighteen months remain – a very short timeframe for a new development to market launch.
Highest Security Requirements
The product must be BSI Basic Protection compliant. All security criteria of the project must be documented and verified.
Complex Logistics
50,000+ packaging units with larger dimensions and weights must be delivered to numerous locations in the shortest possible time. This requires extensive storage capacities and a precisely coordinated supply chain.
Global Coordination
Teams in Germany and Asia, as well as numerous stakeholders on the client side, at ALMEX, in the parent company, and at suppliers, must collaborate closely and seamlessly across multiple time zones.
The central question is: Is it even possible to develop, certify, and produce such a complex, security-critical system at this speed?
For ALMEX, the answer is: Yes – if you are courageous, learn quickly, and perfectly interlink all Performance modules.
The Solution: Five Performance modules, one goal
ALMEX BUILD-TO-RUN IN ACTION
ALMEX deploys all five Performance modules of the Build-to-Run approach, perfectly orchestrated, around the clock and across time zones. This turns a vision into reality.
ALMEX CONSULTING
Strategic Foundation for a Project in New Territory
At the start of the project, there is an initial concept, preliminary technical considerations, and an early prototype demonstrating the system’s basic idea. ALMEX CONSULTING lays the strategic foundation.
Business Analysis:
Together with the client, requirements are refined and described in a comprehensive detailed concept.
System Architecture:
Development of a modular architecture that meets both technical and security requirements – BSI-compliant from the outset.
Requirements Management:
Functional and non-functional requirements are systematically recorded and documented – understandable for all stakeholders, auditable for auditors.
Technology Roadmapping:
Suitable technologies, components, and suppliers are identified and selected in close consultation with the client. Risks are systematically assessed to avoid misinvestments.
The Added Value:
The close integration of requirements management and technology ensures that the project starts in the right direction from the beginning. Changes are not expensively corrected retrospectively but integrated early on.
ALMEX ENGINEERING
From Mockups to Prototypes to Technical Perfection
ALMEX ENGINEERING brings the technical vision to life at record speed and with the highest precision.
Mockups & Prototypes:
Tangible mockups of various parts are created in the first few weeks to validate the design. Iterative development and rapid prototyping enable early detection and correction of errors.
Hardware Design:
Mechanical components, housings, and assemblies are developed – optimally matched to electronics and security requirements. Installation space, cooling, EMC requirements, and ergonomics are considered from the outset.
Electronics:
The core electronic systems, circuits, and PCBs are developed, designed for EMC compliance, and professionally supported through certification.
Software Design:
Embedded software and firmware are designed for robustness, efficiency, and security-critical requirements.
Pre-Certification & Tests:
Environmental and climate tests, EMC tests, functional and electrical tests are carried out in parallel. Continuous coordination of pre-series devices ensures quality.
The Key Feature:
Parallel development in Germany and Asia makes it possible to work almost around the clock. What is developed in Germany is tested in Asia – and vice versa. A seamless engineering flow that saves time and ensures quality.
ALMEX MANUFACTURING
Scalable Production under BSI Requirements
The production of a highly security-critical system requires more than just machines – it requires expertise, infrastructure, and speed. ALMEX MANUFACTURING delivers it all.
Setup of a BSI-compliant Factory:
A factory in Asia is rebuilt, renovated, and set up to be BSI-compliant in record time. Security entrances, dedicated PC networks, barbed wire, and security personnel meet the strict requirements.
Cleanroom Manufacturing:
A cleanroom is set up for particularly sensitive components. Employees work under camera surveillance and with enhanced security requirements.
Global Procurement:
The Asian colleagues leverage their network to find suitable electronics and optics suppliers. Joint developments ensure customized components.
Quality Assurance:
Continuous audits and coordination – both with the client and at the manufacturing sites in Asia – ensure high product quality.
Industrialization:
The transition from prototype to series production is enabled by design-for-manufacturing, process optimization, and supplier qualification. Production lines can be scaled up and down project-specifically.
The Special Highlight:
ALMEX SERVICES
From Rollout to Ongoing Operation
Delivery is just the beginning. ALMEX SERVICES ensures that the systems perform reliably, efficiently, and long-term in the field.
Logistics Masterpiece:
Larger packaging units of various sizes are delivered to different locations in the shortest possible time. Logistics partners provide necessary storage space and transport capacities.
Stock Management:
Intelligent warehousing and efficient inventory management ensure high availability and enable fast, reliable deliveries.
Repair & Maintenance:
Required services are carried out immediately at the Hanover site. Our own Repair Center enables fast response times and minimizes downtime.
Lifecycle Management:
Support throughout the entire product lifecycle – from development to long-term maintenance – ensures availability.
The Advantage:
ALMEX PROJECTS
Overall Project Management as a Success Factor
The complexity of this project requires professional project management at the highest level. ALMEX PROJECTS coordinates all stakeholders, locations, and processes – from the initial idea to the final delivery.
Global Team Coordination:
Teams in Germany (Hanover) and Asia work hand in hand. The time zone difference is deliberately utilized: questions from Germany are answered immediately in Asia – and vice versa. This creates a 24-hour work rhythm.
Stakeholder Management:
Regular coordination with the client, joint audits in Germany and Asia, and continuous communication measures ensure that all stakeholders are always on the same page.
Risk Management:
Early identification of risks (e.g., supply bottlenecks, certification hurdles) and proactive countermeasures prevent costly delays.
Schedule Control:
Stringent milestone planning and consistent monitoring ensure that the project is completed on time despite all its complexity.
The Decisive Advantage:
Without comprehensive project management, this endeavor would have failed. ALMEX PROJECTS ensures that many individual parts become a functioning whole – on time and within budget.
The Result
SUCCESSFUL COMPLETION
This project demonstrates what is possible when all Performance modules interlock perfectly.
Delivered On Time
Highest Quality
All industrial quality and security requirements (BSI Basic Protection, continuous audits) are met. The product meets demanding client requirements.
Successful Market Entry
The systems are successfully on the market today and are used to the satisfaction of users and the client.
“The project is a calculated risk from the start. But we dare to take it. Because that’s exactly our spirit: We fearlessly venture into new territory.”
— ALMEX Project Team
What Makes the Difference?
Global Collaboration
The combination of German engineering leadership and Asian manufacturing speed makes it possible to work around the clock. The time zone difference is deliberately used as an advantage.
Courage to Take Risks
ALMEX shows courage and starts the project early, as time pressure demands it. This pioneering passion distinguishes ALMEX from other service providers.
Flexibility
Changes in the project are not seen as a problem, but as an opportunity. Close cooperation with the client makes it possible to react quickly to new requirements.
End-to-End Competence
Because ALMEX provides all Performance modules from a single source, there is no friction between different service providers. Everything is perfectly coordinated.
Ready for your Build-to-Run project?
Let us industrialize your innovation together – with flexibility, speed, and 50 years of engineering expertise. From idea to operation.