Factory Logistics Optimized internal logistics

In some industrial sectors, route trains are used to replace production supplies with stackers. They transport material to the production lines according to tight schedules on stipulated routes. The route train control and optimization is a complex planning and management task involving numerous variables.

SYNCROTESS transport control system offer the route train control process:

• Rigid and flexible needs-driven schedules and routes
• Requirement forecasts for the coming week
• Reduced distances and empty runs
• Optimized use of load capacities and vehicle circuits
• Consideration of coupling or uncoupling processes in the schedule
• Factoring in breaks or special conditions of individual operating areas
• Dynamic replanning, situational and in realtime for departures from the schedule

Internal logistics has great optimization potential. Although many companies trim their production process to maximize efficiency with automation technology, they control much of the internal material flow by 'gut feel'. Many companies only use IT support for warehouse management or forklift control systems. These systems, however, permit only simple calculations for the transport order element.

Simple forklift control systems have only limited processes available for matching orders to resources. If a spontaneously transport request arises, the nearest unit is normally used. Forklift control systems however have no overview of the overall situation in a plant.

Optimizing transport control systems generally work differently to a forklift control system. The prerequisite is that when such systems are introduced, the transport resources are "pooled". Consequently, the response to transport orders can be more flexible and faster than a "mosaic" from forklifts, tuggers, trailers and other transport resources to be controlled. In practice, only one order is assigned to a forklift and its current status and logistical overall situation is considered. Productivity gains can be achieved only through intelligent optimization in combination with the pooling.

The annual running costs of a simple industrial truck amount to between EUR 35,000 to EUR 55,0000 p.a. (mainly staff costs, though also operating resources, maintenance, financing/leasing, etc.) per shift.

Therefore a 15% reduction in the fleet from 20 vehicles per shift to 17 vehicles equals an annual reduction in costs between EUR 105,000 and EUR 165,000 p.a. and, depending on the system configuration, and amortization of the transport management system within nine to 18 months.

These annual cost savings increase with the following scenarios:

• for two- and three-shift operation by between 80% and 150%
• by 30 instead of 20 vehicles by 50%
• with an increase in efficiency of 20% (instead of 15% as assumed above) an additional 25%
• by a further, additional factor if vehicles are used with running costs higher than EUR 80,000 p.a. incl. staff and incidental expenses
• in the following years T = 2, 3, 4, 5, … by the annual increase in these running costs, in particular for labour and fuel

This is why the transport management system can actually pays for itself in less than a year in the majority of cases.