Pioneering project for Tugger Train Control with SAP®

Tugger trains have become an integral part of logistics - they are already in use on many company and factory premises. They are mainly utilized in production supply and disposal.

Tugger trains are complex systems whose planning and development have received a lot of attention in recent years - the MuCRoute project started in January 2019 in cooperation with the Technical University of Munich. As part of the project, the tugger train system is to be further refined and optimized.

The aim of this cooperation between Würzburger Flexus AG and the Institute of Materials Handling and Material Flow Logistics at the Technical University of Munich is to comprehensively facilitate the troubleshooting of problems in the use of tugger trains. This innovative project is supported by the Bavarian State Ministry of Economic Affairs, Regional Development and Energy.



The FLX-TLS Material Guidance System of Flexus AG already contains a tugger train control, which is directly integrated in SAP® ERP. The transport control system FLX-TLS optimizes the control and coordination of the tugger trains in the material supply and disposal.

The optimization and control algorithms shorten the transport routes for material supply by calculating the most sensible routes in advance. Past data and the actual distance between the destinations are used in the planning of departure and time routes. The joint project with the Technical University of Munich will further refine tugger train control for SAP® and adapt it to customer requirements.



In the future, the tugger train will also react to negative influences and external events (e.g. obstacles on the way). The new add-on will identify known faults and propose remedial measures or solutions, as well as record previously unknown faults. For this purpose, a comprehensive analysis of the components and influencing variables of a tugger train system is defined and a catalogue of requirements is developed.

Key figures play a decisive role: already known key figures are included in the calculation and new key figures are defined. The data volume is then examined for content-related and mathematical correlations.

The validation of the results is carried out on the basis of historical data templates and test runs in existing tugger train systems. By using the SAP® Add-Ons, users will be able to filter and display individually required information in the future. The end user benefits from the different views according to the needs as well as the self-learning algorithm, which documents the causes of errors and shows appropriate solution strategies.

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