Factory Logistics Optimized internal logistics

Efficient logistics and in-plant supply chains require optimized in-plant transportation management. And the supply of
parts and materials to the factory floor should be actively synchronized with the manufacturing process.


An efficient transport control system optimizes both the use of vehicles (forklifts, trucks, tractors, tugger trains etc.) and also the scheduling of transport assets (trailers, containers etc.) for internal logistics. Transport orders are generated, inbound and outbound deliveries are organized, storage positions are managed, and loading and unloading runs are initiated - all in a fully automated and transparent manner.

The transport management system renders in-plant materials handling:

  • more transparent, reliable, and on-time
  • better synchronized with the manufacturing process
  • significantly more efficient and productive (15% - 35%).

The transport control system provides rapid response to any ad-hoc tasks and rush jobs. It finally provides online tracking & tracing of materials, vehicles, trailers, and other assets, as well as dedicated KPI reports on the entire in-plant supply chain.


Solution SyncroTess Features

The SyncroTESS transport management system supports the centralized control and optimization of all logistics flows in the company. The logistics processes can be synchronized with production, effectively reducing manual input.

  • Realtime control

    All relevant information is combined for scheduling, control and monitoring of resources and transport orders. The system uses this information to then create optimal matches between orders and resources.

  • Material tracking

    Information generated by the logistics process is stored in the system and historical operational detail is accessible at any time.

  • Multi-stage concept

    SyncroTESS uses master data to detect whether several transport stages - sometimes with varying resource requirements - are needed to complete an order. Orders that need multi-stage transport include cross-hall runs across stations, rack placements and removals via transfer positions, as well as transport runs using elevators and conveyor belts.

    The transport chains are therefore automatically assigned to the relevant resources.

  • Management of trailers and containers

    All types of passive transport asset (e.g. trailers, containers, frames) can be scheduled and managed in terms of location and timing. All units are therefore clearly identifiable.

  • Warehouse management

    The transport management system supports the running of simple warehouses. In addition to material tracking, the system permits storage location management, storage and removal tracking, management of minimum and maximum stocks, and the generation of transport orders.

  • Integration

    Standard interfaces allow simple and efficient integration into customer legacy systems. One such interface betrween the transport management system and third-party systems is the API. The system can also be bi-directionally linked to an SAP interface for transmitting transport orders and their feedback. INFORM has certified three interfaces to the SAP system. Specifically, the PP-POI, the MM-MOB and the WM-LSR interfaces.

  • Simulation

    Simulation methods enable "what-if" analyses. The simulation process allows users to model scenarios relating to shift manpower, shift timing, the transport network or optimization strategies in the system and consider the resulting impacts.


The SyncroTESS transport management system enables companies to achieve a fully automated and transparent supply chain. Thanks to the scalability and modular structure of the software, the intralogistic requirements of various sized companies can be achieved.

  • Minimized empty runs

  • Improved fleet utilization

  • Shorter throughput times

  • Lower transport costs

  • Increased productivity

  • High degree of transparency

  • Reduced control effort

  • Meaningful KPIs and reports

Route trains

Control route trains efficiently

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

Forklift control system vs. Transport control system

Forklift control system vs. Transport control system Internal transport control with regard to the overall material flow

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.


Measured advantages Faster amortization

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.


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