Just-in-time deliveries, increasing demands for flexibility and real-time traceability of every component. In today’s automotive industry, logistics is about far more than transporting parts from A to B. At Automotive Painting Partners (APP), it is a vital part of an integrated manufacturing supply chain serving leading OEM partners across Europe. We spoke with Zdeněk Půlpitel, Head of Logistics at APP, about meeting these demanding requirements, why cross-docking is more efficient than traditional warehousing, and the role digitalisation plays in modern automotive logistics.
Mr Půlpitel, as Head of Logistics, you oversee the processes that connect Automotive Painting Partners’ manufacturing operations with the assembly lines of leading global automotive manufacturers. What, in your opinion, makes logistics at APP unique?
What makes logistics at Automotive Painting Partners unique is that we are much more than a warehouse or a transport provider. We are an integral part of the entire manufacturing supply chain – from component sourcing and welding to cathodic electrocoating, packaging and direct deliveries to OEM partners. This gives us complete control over the flow of materials and enables us to respond quickly and flexibly to our customers’ requirements. A key role is played by our logistics centre in Zvěřínek, which serves as a central hub for both cross-docking operations and direct deliveries to leading automotive manufacturers across Europe.
APP presents itself as a strategic partner offering a complete solution, from component sourcing through to final dispatch. What benefits does this one-stop-shop model provide for your customers?
Logistics is the central link that holds the entire model together. Because APP brings manufacturing, surface treatment, assembly and dispatch together under one roof, our customers do not have to coordinate multiple suppliers or manage transport between different facilities. This not only delivers significant time and cost savings but also provides greater visibility and control over the entire supply chain.
Could you explain how your department contributes to this model and what your role involves?
Our department is responsible for shipment consolidation, transport route optimisation and efficient dispatch planning. By minimising the number of handling operations, we reduce both the risk of component damage and unnecessary logistics costs. For automotive manufacturers, one of the greatest advantages is having a single accountable partner who manages the entire process – from the incoming component through to the delivery of the finished product directly to the production line.
My role is primarily focused on coordinating logistics processes across manufacturing, warehousing and final dispatch to our OEM partners. At APP, we ensure that every component moves smoothly through the entire process, without unnecessary delays and with maximum control over quality and delivery performance. I lead a team responsible for daily delivery planning, customer communication and responding to operational changes in production.
APP uses a cross-docking model alongside direct deliveries. What are the main benefits for OEM partners, and how do these processes differ from traditional warehousing?
Cross-docking is based on the rapid flow of materials without the need for long-term storage. Components move directly from production to our logistics centre, where they are immediately sorted, consolidated and prepared for individual customers. This significantly reduces lead times while eliminating unnecessary inventory.
Direct deliveries mean fewer intermediate handling stages, reducing both the risk of errors and the potential for component damage. As a result, our customers can rely on on-time deliveries, benefit from greater visibility of material flow and reduce their own warehousing costs. Unlike a traditional warehouse, the focus is not on long-term storage but on ensuring the fastest and most efficient movement of components throughout the entire supply chain.
In the automotive industry, every minute counts, and OEM partners depend on precise, on-time deliveries. How does APP consistently meet these demanding expectations?
The foundation is a well-structured process, digitalisation and an experienced team. Every stage of our logistics operation is clearly defined and continuously monitored. Our manufacturing, quality and logistics teams work closely together to ensure smooth operations. One of APP’s key strengths is our two identical production facilities which provide full operational redundancy and significantly enhance supply reliability. We also use advanced shipment tracking systems, transport planning tools and rigorous quality control procedures. Together, these enable us to consistently meet the demanding requirements of the automotive industry over the long term.
Flexibility is also essential in logistics. How do you respond to unexpected changes in customer orders or production schedules? What makes the difference in these situations?
In the automotive industry, change is part of everyday reality, so we build our processes with that in mind. The key to success is fast communication, accurate data and the ability to quickly adjust both logistics operations and production capacity.
Because our logistics, manufacturing and dispatch functions are closely integrated, we can rapidly reprioritise orders, adjust loading schedules and optimise transport in line with our customers’ changing requirements. Another major advantage at APP is our high level of automation and digitalisation, which allows us to respond with agility while maintaining stable and reliable deliveries.
APP supplies components to leading automotive manufacturers across Europe. Do you notice differences in logistics communication and collaboration between different countries?
Absolutely. For example, our German partners place an exceptionally strong emphasis on precision, process discipline and strict adherence to delivery time windows. In France and Southern Europe, communication tends to be more flexible and often places greater value on personal relationships and day-to-day coordination. Regardless of the market, however, automotive customers share the same core expectations: transparency, responsiveness and the ability to consistently meet clearly defined standards. At APP, we have extensive experience working with a wide range of OEM partners, and we tailor our logistics processes to meet their specific requirements.
A significant share of APP’s production is supplied to the German market. What do you see as the key advantages of your logistics model for German customers?
For our German customers, stability, precision, process transparency and strict adherence to delivery time windows are essential. Having worked with them over many years, we have designed our logistics processes to consistently meet these demanding expectations.
Another key advantage is the strategic location of our logistics hub in Zvěřínek, combined with an efficient cross-docking system and meticulous transport planning. We package components in accordance with specific OEM standards, and the entire process is digitally monitored. This enables us to guarantee accurate just-in-time and just-in-sequence deliveries while minimising the risk of production disruptions at our customers’ facilities.
IATF 16949 certification is one of the key standards in the automotive industry. How do its requirements influence day-to-day logistics operations?
The stringent quality and process management requirements of IATF 16949 influence virtually every aspect of our daily operations. All logistics processes are standardised, documented and regularly audited, while every component must be fully traceable from the moment it enters production through to its final dispatch to the customer. When handling coated components, we place the highest priority on protecting the finished surface, using the correct packaging, ensuring the cleanliness of packaging materials and complying with defined handling procedures. The entire system is supported by regular employee training, internal audits and a proactive approach to risk management.
Cathodic electrocoated surfaces are susceptible to mechanical damage during transport. What packaging and securing methods do you use to guarantee the quality of the coated surface, even during long-distance shipments?
We use specialised automotive packaging solutions designed specifically for each component type and the requirements of the individual OEM customer. Our priority is to minimise contact between components and eliminate vibration during transport. To achieve this, we use securing elements, protective separators, returnable packaging and purpose-designed transport racks. Every packaging solution undergoes testing and validation to ensure maximum protection of the cathodic electrocoated surface during long-distance transport across Europe. We also place great emphasis on careful handling throughout the loading and unloading process.
What systems do you use for order tracking and data exchange to ensure customers always have full visibility of their orders?
We rely on modern digital systems for material flow management, shipment tracking and dispatch planning. This ensures that every component and every shipment can be tracked in real time. We communicate with our customers through standard automotive data interfaces, EDI communication and regular reporting, giving them continuous visibility of production, packaging and transport status. Today, data transparency is a fundamental expectation in the automotive industry, and for us it is also the foundation of long-term customer trust.
APP places great emphasis on environmental responsibility. How do you optimise your logistics operations to minimise the carbon footprint across the entire supply chain?
We focus on making the most efficient use of transport capacity while minimising empty mileage. By consolidating shipments at our logistics centre, we can optimise transport routes more effectively and reduce the number of individual deliveries. Our transport planning takes both environmental efficiency and the long-term sustainability of the entire supply chain into account. Returnable packaging systems also play a significant role, helping us substantially reduce the amount of single-use packaging waste.
The automotive industry is rapidly moving towards greater digitalisation and automation. What innovations do you expect to see in logistics and dispatch over the coming years, and how is APP preparing for them?
Looking ahead, automotive logistics will become increasingly driven by automation, data analytics and predictive planning. We also expect much closer real-time integration between logistics systems and customers, along with a growing role for artificial intelligence. At APP, we are preparing for these developments through the gradual digitalisation of our processes, ongoing investment in modern technologies, and a strong focus on automation across both manufacturing and logistics. Our goal is not only to remain a reliable supplier but also to be a technologically advanced partner that keeps pace with industry developments and responds flexibly to the evolving demands of the automotive sector.
