Production Logistics: Plan, Optimize, Automate

Efficient Production Logistics
Challenges in Production Logistics
Designing Material Flow
FAQs about Production Logistics

What characterizes efficient and economical production logistics?

Whether production logistics, intralogistics or internal logistics: Regardless of its internal company name, the design of logistics processes from goods receive through production supply to dispatch is at the center here. An efficient, trouble-free material flow is the key success factor that connects the value stream. On the one hand, this holistic impact indicates the achievable effect of optimized production logistics and, on the other, reflects the complexity of the task.

Together we will develop an efficient, economical production logistics system so that you can focus on your value-adding activities.

Start Consulting on Production Logistics About the 5 Levels of Planning

Current Challenges in Production Logistics

Operational costs and increasing Growth

High operating costs, especially in personnel and storage, are often indicators of possible optimization potential in your production logistics. But even efficient logistics processes can reach their limits when growth exceeds existing capacities. In these cases, it is not uncommon for the creativity of the operational business to kick in whereby increasing requirements are met with the help of interim solutions.

Without organizational and procedural intervention, however, inefficiencies manifest themselves, causing the overall system to gradually distance itself further from the operational optimum. This can cause problems, which can even lead to downtimes of assembly or production lines.

Advanced manufacturing facility with robotic arms and autonomous mobile robots (AMRs) ensuring efficient material handling and compliance with process requirements

Material and process requirements

In many industries, specific material and process requirements must be taken into account, for example to prevent contamination of components and products. The production of medical products or battery cells are just two examples.

Production logistics is directly affected by these requirements, as it is the connection between the individual manufacturing steps. For example, person and material locks must be designed as transitions between areas with different cleanliness requirements. We work with you to analyze your individual requirements and integrate them into the overall production logistics system.

Diversity of variants and increasing complexity

Furthermore, an increasing number of variants and growing complexity due to the integration of external service providers, repackaging activities or load carrier changes present additional challenges when planning production logistics. The result is an attitude of expectation towards the system that brings together two fundamentally conflicting objectives.

On the one hand, a highly efficient system for enabling value-adding processes is to be established through standardization.
On the other hand, the system should at best also have an inherent flexibility framework that enables a short-term response to changes at any time.

This conflict of objectives requires a comprehensive project approach. We view production logistics as an integral part of the factory, always taking into account the interactions with other functional areas. With the help of an incremental analysis of your production logistics system, you can identify the fields of action with the greatest potential. The foundation is a comprehensive data analysis, on the basis of which production logistics can be designed realistically.

Design Future-Oriented Material Flow Now

How to design material flow and logistics systems optimally?

5 steps to planning production logistics

1. Step: Building design

The first step is to analyze the existing "playing field", which in the production context is defined at the highest level by the building design. This first step is important in order to understand the fixed points defined by the building, which increase or limit the possible scope for design accordingly.

2. Step: Space allocation

In the next step, the "inner life" of the factory is revealed from a functional perspective. The segmentation of the total area in the level of detail required for the individual project (area → sub-area → workstation) expresses the underlying factory structure. In the best-case scenario, this step already identifies the areas that were planned at the initial time and those that have grown historically and unstructured over time.

3. Step: Area relationships

Once the building design and areas are known, the procedural level is entered. The network of relationships in the layout reveals which source-sink relationships and area dependencies exist. A deep methodological expertise is required for this work step in order to convert the retrievable mass data from heterogeneous sources into homogeneous, manageable formats. Depending on the complexity, we use classic database applications or linked analysis tools (e.g. MS Power BI) for the implementation.

4. Step: Material flow design

The processed data is the basis for organizing the material flow in a target-oriented manner. Taking into account the intensities and volumes between the individual area relationships as well as the suitable buffer and material supply concepts, the material flow is transferred into a structure that can be modelled in reality. The material flow is designed on the basis of the target scenario so that you can operate your system at its optimum level for as long as possible.

5. Step: Overall system and economic efficiency evaluation

The final step is to make the developed system ready for implementation by selecting suitable subsystems. The issue of automation in the selection of storage systems and materials handling equipment is rapidly gaining in importance due to limited availability and increasing competition for skilled labour.

In addition to evaluating the functional suitability of possible alternative solutions, economic factors also play a decisive role. The decision-making process can be supported by economic efficiency analyses. The investment volume must be justified by operational cost effects so that the implemented system is still seen as a success at a later date.

Enquire a Customized Concept

Procure production logistics equipment

For us, the completion of the analysis and planning phase does not mean the end of the project. If necessary, we then go through the entire tendering and awarding process for the procurement of the required equipment.

The functional specification of all characteristics plays a major role, especially if highly automated systems have to be customized. We are at your side from the pre-selection of suitable system providers through to support during the award discussions.

Comissioning and ramp-up support

During implementation, our main focus is on taking the functional user's point of view and ensuring that the realization is in line with planning. The same applies to the interface to IT, which is a critical success factor for integrating new systems. With a detailed briefing, we enable your IT experts to translate the functional requirements into your system landscape. During the final system implementation, we ensure a high level of on-site presence to closely support your team in all tasks. Together, we coordinate and control the assembly of the systems, support you during the commissioning and ramp-up phases and bring the respective system up to the desired performance level during the ramp-up phase.

Metroplan actively supported us in successfully realizing the move to the new logistics property.
realization. The competent planning of the utilization concept and coordination of the trades involved
trades involved contributed significantly to the fact that we were able to continue to supply our customer
in sequence as we changed location. We are very satisfied with the trustful cooperation.

Volker Klemm // CEO - Logistik Schmitt

FAQs about Production Logistics

How can automation and flexibility be combined in a production logistics system?

Automation and flexibility are often formulated as opposites in production logistics design. While automation is seen as a basic prerequisite for a high degree of standardization, flexibility is often associated with frowned upon requirements such as extensive buffer capacities. However, an integrative production logistics system combines both requirements. The basis for this is intelligent logistics for planning and control, adaptive routing and a coordinated interface between transport systems and warehouse technology.

What role does material flow simulation play in production logistics planning?

Increasing requirements from a product and process perspective are increasing the complexity of production logistics. As an enabling component in complex production environments, production logistics ensures supply and disposal in the production and assembly areas. In particularly complex (sub-)areas, static considerations are sometimes no longer sufficient to anticipate system behavior during planning. With the targeted use of a material flow simulation, sensitivities can be mapped at an early stage and bottlenecks identified in order to optimize the design on this basis.

What do I need to bear in mind when introducing AGVs (Automated Guided Vehicles)?

The successful planning and introduction of AGVs requires the consideration of important factors. Below you will find five important success drivers: