Your route trains run according to plan. But is the plan optimal?
Fixed routes also run when there is no demand. FlexGuide4 only calculates the route when the need arises. Directly in SAP, can be combined with forklifts and AGVs.
50 million+
Driving orders generated
Brose, 17+ locations worldwide
1.000
Driving orders per day
KNOLL, mixing fleet incl. 2 tugger trains
< 0,1 %
Error rate
KNOLL, forklifts + tugger trains + AGVs
Why FlexGuide4
Route train control that thinks for itself
Anyone who has ever seen a tugger train making an empty tour understands the problem. FlexGuide4 plans the tour based on the current demand.
Fully dynamic route planning
Fixed, fully dynamic or permanent routes. FlexGuide4 calculates the optimum route based on demand, distance and time window. No more rigid cycles.
Trailer management in SAP
Location, loading status and contents of each trailer, live in SAP. B/C frames and picking coaches, fixed and mobile trailers, sorted and unsorted loading.
Mixed fleet-capable
Control tugger trains together with forklifts and AGVs via one system. KNOLL operates 14 forklifts, 2 tugger trains and 3 AGVs in one fleet, with an error rate of less than 0.1%.
Cockpit & Visualization
Scheduled orders, route status and capacity utilization, all in the cockpit in real time. Transport orders can be processed and prioritized directly.
Handsfree loading & unloading
Tugger train drivers work hands-free with back-of-hand scanners (NIMMSTA HS50, ProGlove MARK Display). Faster scanning processes, fewer errors during loading and unloading.
Working time models & breaks
Order determination takes working time models, breaks and planned times into account. Tours are planned realistically. No overload, no idle times.
How it works
From the material requirement to the optimized tour
01
Demand arises
Material requirements from SAP (production, warehouse, shipping) or via worker dialog flow into the central order pool.
02
Tour is calculated
FlexGuide4 calculates the optimum route: distances, time window, trailer capacity and loading sequence.
03
Driver works off
Tour appears on the terminal. Hands-free scanning processes at every stop. Loading and unloading with barcode acknowledgement.
04
SAP is informed
Every acknowledgement flows back to SAP in real time. Cockpit shows progress, capacity utilization and key figures.
References
Companies that control tugger trains with FlexGuide4
EvoBus (Daimler)
production supply
Central logistics control for tugger trains and forklifts in bus production in Neu-Ulm. Demand-oriented picking, real-time control in SAP S/4HANA.
SAP S/4HANA platform
Brose vehicle parts
Global rollout
17+ locations in 24 countries. AGVs, forklifts and tugger trains combined in a template approach. A new location will go live in a few days.
50 million + transport orders
KNOLL Mechanical Engineering
Mixed fleet
14 forklifts, 2 tugger trains and 3 Safelog AGVs in one fleet, controlled by one system. 1,000 transport orders per day with an error rate of less than 0.1%.
< 0.1 % error rate
Areas of application & functions
More than just route planning
From the material request until the trailer is back on site. Not a single step is missing.
Fixed, dynamic & permanent tours
Three tour models in one system. Fixed routes for stable requirements, fully dynamic routes for fluctuating requirements, permanent routes for long-distance runners.
Trailer types & loading capacities
Manage different trailer types with different loading capacities. Reservation and allocation to the respective route automatically.
Loading & unloading strategy
Sorted and unsorted loading strategies. FlexGuide4 takes into account loading and unloading processes over the course of the route.
Multi-stage transports
Transfer between tugger trains and forklifts. Automatic transport order creation from production orders or manually via worker dialog.
Handsfree scanner
NIMMSTA HS50 (45 g) and ProGlove MARK display. Hands-free scanning processes speed up loading and unloading on the tugger train.
Expandable to a mixed fleet
Tugger train control as a single module or combined with forklift guidance system and AGV control. One system for all transport resources.
SAP Integration
Seamlessly integrated into SAP
FlexGuide4 is SAP-certified (S/4HANA) and works directly with your existing SAP modules.
SAP EWM & WM
Tugger train orders directly from SAP Warehouse Management. Acknowledgements and status messages back into the system in real time.
SAP PP & MM
Production supply via tugger train from production orders. Material requirements from MM trigger tours automatically.
SAP S/4HANA
Certified for S/4HANA. EvoBus (Daimler) is already using FlexGuide4 productively on S/4HANA, including tugger train control.
Frequently asked questions
FAQ: Tugger train control for SAP
What is the difference between fixed and fully dynamic tugger train control?
With fixed control, the tugger train follows a fixed route according to a timetable. With fully dynamic control, FlexGuide4 calculates the route in real time based on current demand: routes, time windows, trailer capacity and loading sequence are optimized for each new route. FlexGuide4 supports both models, plus permanent tours as a third model.
Can tugger trains be controlled together with forklifts and AGVs?
How does trailer management work?
Are working time models and breaks taken into account?
Do I need special hardware for the tugger train drivers?
Can I also use the tugger train control individually?
Does this work with SAP S/4HANA?
Can the system be rolled out at other locations?
Book a free consultation appointment
Ready to control your tugger trains intelligently?
Talk to our experts –
non-binding, specific and tailored to your SAP landscape.
Sascha Scherer
FlexGuide4 for worry-free intralogistics
phone: +49 931 466 211 100