In use at ZF, MANN+HUMMEL and EvoBus

Forklift guidance system for SAP

FlexGuide4 manages your forklift fleet directly from SAP. Route-optimized and prioritized, with full transparency.

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46%

fewer forklifts required

ZF Friedrichshafen, production logistics

1 million+

Transport orders in 6 months

MANN+HUMMEL, order picking and shipping

6 to 18 months

average ROI

Across all FlexGuide4 projects

Why FlexGuide4

The forklift guidance system that reduces 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 by route and priority. Empty runs are minimized and distances shortened, measurable from day one.

Full transparency in SAP

Every transport, every status, every confirmation, live in SAP. No material goes missing, no forklift sits idle unnoticed. Cockpit for the control center.

WIP inventory management

Manage materials that are not yet stocked in the SAP warehouse down to the exact location. Work-in-process inventory transparent in SAP, as at ZF Friedrichshafen.

All resources, one system

Forklifts, narrow-aisle trucks, electric pallet trucks, mobile employees, all in one system. Expandable with tugger trains, AGVs and mobile robots for a true mixed fleet.

Mobile order processing

Transport orders directly on the forklift terminal or via the FlexMobile app on a handheld. Paperless and scanner-supported.

Dashboards and reports

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

How it works

From transport requirement to optimized transport order

Order is created

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

Optimization

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

Assignment

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

Transparency

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

References

Companies that control their forklifts with FlexGuide4

ZF Friedrichshafen

Production logistics

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

46% fewer forklifts

View reference →

MANN+HUMMEL

Shipping logistics

Faster picking and shipping processes. Order distribution across delivery notes, 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 reduced the number of forklifts required from 13 to 7. Talk to us about your potential.

View ZF reference → Request a consultation

Areas of application

One forklift guidance system, all logistics areas

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

Production supply

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

Warehouse and order picking

Order distribution across delivery notes to narrow-aisle trucks. STILL, Crown and Jungheinrich integration for semi-automatic forklift control.

Goods receipt and goods issue

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

WIP inventory management

Manage semi-finished products in SAP down to the exact location, 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

Add new sites easily. Transfer routes, transport resources and configurations via template, proven at Brose with 17+ sites.

SAP Integration

Integrated directly 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 requests from MM. Multi-stage transports across all SAP modules.

SAP S/4HANA and Cloud

Certified for SAP S/4HANA. EvoBus already uses FlexGuide4 productively on S/4HANA. On-premise and cloud supported.

Frequently Asked Questions

FAQ: Forklift guidance system for SAP

Average ROI times are 6 to 18 months, depending on project scope. ZF Friedrichshafen reduced the number of forklifts required from 13 to 7. Thanks to the efficiency gains, MANN+HUMMEL did not need to hire four additional employees.

Yes. Semi-automatic narrow-aisle trucks are 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 technology, because distances and pick-up and drop-off points are already known from the graphical planning tool. Laser or UWB radio localization can be integrated as an option, but is not a requirement.

Yes. Multi-stage 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 put away and removed at the exact location. ZF Friedrichshafen uses this to manage semi-finished products in forming technology.

No. Personal data is never stored. All reports relate to the device or resource, never to individual employees.

Yes. The components of the forklift guidance system make rollout to other sites easy. Physical route changes, new transport resources or rollouts within your group can be handled with the existing tools.

Yes. The forklift guidance system is SAP-certified for S/4HANA. EvoBus (Daimler) already uses FlexGuide4 productively on SAP S/4HANA. SAP Fiori is supported as well.

Book a Free Consultation

Ready to control your forklift fleet intelligently?

Talk to our experts about your SAP landscape, with no obligation.

Sascha Scherer

FlexGuide4 for worry-free intralogistics

phone: +49 931 466 211 100

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Forklift guidance system for SAP