In use at ZF, MANN+HUMMEL and EvoBus

Your forklifts are moving – but do you know where they are going?

When forklifts drive on demand, empty runs, waiting times and blind spots arise in the material flow. FlexGuide4 controls your forklift fleet directly from SAP, route-optimized, priority-controlled and with full transparency.

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SAP Silver Partner Badge

50 %

fewer forklifts required

ZF Friedrichshafen, Production Logistics

1 million+

Driving orders in 6 months

MANN+HUMMEL, order picking and shipping

6-18 Mon.

average ROI

About all FlexGuide4 projects

Why FlexGuide4

Forklift control that eliminates empty runs

No calling out, no paperwork, no blind spots. FlexGuide4 turns your forklift fleet into an intelligently controlled transport system, directly in SAP.

Route optimization

Transport orders are assigned in a route-optimized and priority-controlled manner. Empty runs are minimized, routes are shortened, measurable from day 1.

Full transparency in SAP

Every transport, every status, every acknowledgement, live in SAP. No material disappears, no forklift goes unnoticed. SLS cockpit for the control station.

WIP inventory management

Manage materials that are not yet stocked in the SAP warehouse with pinpoint accuracy. Work-in-process inventories transparently in SAP, as at ZF Friedrichshafen.

All resources, one system

Forklift trucks, narrow-aisle forklift trucks, electric forklift trucks, mobile employees, all via one system. Expandable with tugger trains and AGVs for a real mixed fleet.

Mobile order processing

Transport orders directly at the forklift terminal or via the FlexMobile app on the handheld. Paperless, scanner-supported, error-reduced.

Dashboards and evaluations

Real-time key figures on capacity utilization, throughput times and transport volumes. Cost center-based billing. No personal data.

How it works

From transport requirements to optimized transport orders

1

Order is created

Automatically from SAP (production, warehouse, shipping) or manually via worker dialog, all sources flow into a central transport order pool.

2

Optimization

FlexGuide4 calculates the best assignment: priorities, waiting times, routes, due dates, configurable according to your rules.

3

Allocation

The optimized transport order appears directly on the forklift terminal or the FlexMobile app. Scanner-supported acknowledgement at the pick-up and drop-off point.

4

Transparency

Status flows back to SAP in real time. Control center, dashboards and evaluations show the material flow seamlessly.

References

Companies that control their forklifts with FlexGuide4

ZF Friedrichshafen

Production logistics

Centralization of the forklift fleet in forming technology. Push/pull material request directly at the machines. WIP warehouse management for semi-finished products in SAP.

-50 % forklift required

View reference →

MANN+HUMMEL

Shipping logistics

Picking and dispatch processes accelerated. Cross-delivery note order distribution, semi-automatic narrow-aisle trucks via STILL OptiSpeed.

1 million+ orders / 6 months

“We were convinced by the fact that Flexus AG has many years of experience in SAP intralogistics.” Roland Prechler, Head of SCM, MANN+HUMMEL

View reference →

EvoBus (Daimler)

Intralogistics platform

Central logistics control for forklifts, tugger trains and mobile employees in bus production in Neu-Ulm. Real-time material tracking in SAP S/4HANA.

SAP S/4HANA platform

“The savings potential of the FlexGuide forklift guidance system convinced us from day one.” Armin Barth, Head of Logistics Bus West Europe, EvoBus

View reference →

How many empty runs could you save?

ZF Friedrichshafen has reduced the number of forklifts required by 50%. Talk to us about your potential.

View reference ZF → Arrange a consultation appointment →

Areas of application

One forklift guidance system, all logistics areas

FlexGuide4 covers the entire internal material flow, from goods receipt to production supply and dispatch.

production supply

Machine-to-machine transports, multi-stage transport orders, push and pull principle. Production order data from SAP automatically triggers transports.

Warehouse and order picking

Cross-delivery note order distribution to narrow-aisle forklift trucks. STILL, Crown and Jungheinrich integration for semi-automatic forklift control.

Incoming and outgoing goods

Barcode-supported material tracking from the entrance gate to the shipping truck. Scanning at the pick-up and drop-off points ensures seamless traceability.

WIP inventory management

Manage semi-finished products in SAP with pinpoint accuracy, even if they are not yet stocked in the SAP warehouse. Container management included.

Trailer management

Manage trailers as a transport resource, store container types and assign transports, all within FlexGuide4.

Multi-site rollout

Simply add new locations. Transfer routes, transport resources and configurations via template, tried and tested at Brose with 17+ locations.

SAP Integration

Seamlessly integrated into SAP

FlexGuide4 is SAP-certified (S/4HANA) and works directly with your existing SAP modules, without middleware.

SAP EWM and WM

Direct connection to SAP Extended Warehouse Management and classic Warehouse Management. Transport orders and confirmations in real time.

SAP PP and MM

Production supply from production orders, material requirements from MM. Multi-level transports across all SAP modules.

SAP S/4HANA and Cloud

Certified for SAP S/4HANA. EvoBus is already using FlexGuide4 productively on S/4HANA. Supported on-premise and in the cloud.

Frequently asked questions

FAQ: Forklift control system for SAP

The average ROI times are between 6 and 18 months, depending on the scope of the project. ZF Friedrichshafen was able to reduce the number of forklifts required by 50%, while MANN+HUMMEL saved four additional employees thanks to the increase in efficiency.

Yes, semi-automatic narrow-aisle trucks are easily integrated via standardized interfaces. Integrations with STILL (OptiSpeed), Crown and Jungheinrich are already available. MANN+HUMMEL uses this productively in its high-bay warehouse.

No. FlexGuide4 also works without localization technologies; distances, pick-up and drop-off points are already known via the graphical planning tool. Laser localization or UWB radio localization can be optionally integrated, but are not a prerequisite.

Yes, multi-level transports between tugger trains and forklifts are integrated in the SAP modules. Transport orders can be created automatically from production order data or manually via worker dialog.

Yes, with FlexWIP warehouse management, materials that are not yet stocked in the SAP warehouse can be stored and retrieved at the exact location. ZF Friedrichshafen uses this for the management of semi-finished products in forming technology.

No. Personal data is not stored at any time. All evaluations relate to the device or resource, never to individual employees.

Yes, the components of the forklift guidance system make it easy to roll out to other locations. Physical changes to routes, new transport resources or roll-outs within your group are easy to implement using the existing tools.

Yes, the forklift guidance system is certified for S/4HANA by SAP. EvoBus (Daimler) is already using FlexGuide4 productively on SAP S/4HANA. SAP Fiori is also supported.

Book a free consultation appointment

Ready to control your forklift fleet intelligently?

Talk to our experts, without obligation, specifically and tailored to your SAP landscape.

Sascha Scherer

FlexGuide4 for worry-free intralogistics

phone: +49 931 466 211 100

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