In use at EvoBus, Brose and KNOLL

Tugger train control with SAP

Q: What is the difference between fixed and fully dynamic tugger train control?

With fixed control, the tugger train follows a set route according to a timetable. With fully dynamic control, FlexGuide4 calculates the tour in real time based on current demand: distances, time windows, trailer capacity and loading sequence are re-optimized for every tour. FlexGuide4 supports both models, plus permanent tours as a third model.

Q: Can tugger trains be controlled together with forklifts and AGVs?

Yes. FlexGuide4 is designed as a mixed-fleet solution. KNOLL operates 14 forklifts, 2 tugger trains and 3 AGVs in one system. Brose combines tugger trains, forklifts and AGVs at 17+ sites worldwide. Multi-stage transports are supported as standard.

Q: How does trailer management work?

FlexGuide4 manages the location, load status and contents of every trailer in SAP. Different trailer types (B/C frames, picking coaches) with different load capacities are supported. The software reserves trailers for tours and takes loading and unloading operations into account over time.

Q: Are working time models and breaks taken into account?

Yes. Order determination takes working time models, breaks and planned times into account. Tours are planned realistically. No overload for individual drivers, no idle time.

Q: Do I need special hardware for tugger train drivers?

FlexGuide4 works with forklift terminals and FlexMobile apps on handhelds. For hands-free loading and unloading, back-of-hand scanners are supported, such as the NIMMSTA HS50 (45 g) or the ProGlove MARK Display.

Q: Can I use tugger train control on its own?

Yes. Tugger train control can be used as a standalone module. It can be expanded at any time with the forklift guidance system and AGV control. All within FlexGuide4, all in SAP.

Q: Does this work with SAP S/4HANA?

Yes. FlexGuide4 is SAP-certified for S/4HANA. EvoBus (Daimler) uses the complete solution, including tugger train control, productively on S/4HANA.

Q: Can the system be rolled out to other sites?

Yes. Brose is rolling out FlexGuide4, including tugger train control, at 17+ sites in 7 countries. With the template approach, a new site can be set up in just a few days.

Fixed routes run even when there is no demand. FlexGuide4 calculates the tour only when demand arises. Directly in SAP, and combinable with forklifts, AGVs and mobile robots.

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50 million+

Transport orders generated

Brose, 17+ sites worldwide

1.000

Transport orders per day

KNOLL, mixed fleet including 2 tugger trains

< 0.1%

Error rate

KNOLL, forklifts, tugger trains and AGVs

Why FlexGuide4

Tugger train control that thinks ahead

Anyone who has seen a tugger train run an empty tour understands the problem. FlexGuide4 plans the tour based on current demand.

Fully dynamic tour planning

Fixed, fully dynamic or permanent tours. FlexGuide4 calculates the optimal route based on demand, distance and time window. No more rigid cycles.

Trailer management in SAP

Location, load status and contents of every trailer, live in SAP. B/C frames and picking coaches, fixed and mobile trailers, sorted and unsorted loading.

Compatible with mixed fleets

Control tugger trains together with forklifts, AGVs and mobile robots in one system. KNOLL operates 14 forklifts, 2 tugger trains and 3 AGVs in one fleet, with an error rate below 0.1%.

Cockpit & visualization

Planned orders, route status and utilization, all in the cockpit in real time. Transport orders can be edited and prioritized directly.

Hands-free loading & unloading

Tugger train drivers work hands-free with back-of-hand scanners (NIMMSTA HS50, ProGlove MARK Display). Faster scanning, fewer errors when 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 time.

How it works

From material request to optimized tour

Demand arises

Material requests from SAP (production, warehouse, shipping) or via worker dialog flow into the central order pool.

Tour is calculated

FlexGuide4 calculates the optimal route: distances, time windows, trailer capacity, loading sequence. Fully dynamic.

Driver processes the tour

The tour appears on the terminal. Hands-free scanning at every stop. Loading and unloading with barcode confirmation.

SAP is updated

Every confirmation flows back to SAP in real time. The cockpit shows progress, utilization and KPIs.

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-driven picking, real-time control in SAP S/4HANA.

SAP S/4HANA Platform

View reference →

Brose Fahrzeugteile

Global rollout

17+ sites in 7 countries. AGVs, forklifts and tugger trains combined in a template approach. A new site can be set up in just a few days.

50 million+ transport orders

View reference →

KNOLL Maschinenbau

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 below 0.1%.

< 0.1% error rate

View reference →

How many empty tours is your fleet running right now?

Brose controls 17+ sites with one system. KNOLL achieves an error rate below 0.1%. Talk to us about your potential.

View KNOLL reference → Request a consultation

Applications & functions

More than just route planning

From the material request until the trailer is back in place. No step is missing.

Fixed, fully dynamic & permanent tours

Three tour models in one system. Fixed routes for stable demand, fully dynamic tours for fluctuating requirements, permanent tours for high-runners.

Trailer types & load capacities

Manage different trailer types with different load capacities. Reservation and assignment to the respective route happen automatically.

Loading & unloading strategy

Sorted and unsorted loading strategies. FlexGuide4 takes loading and unloading operations into account along the route timeline.

Multi-stage transports

Handover between tugger trains and forklifts. Automatic transport order creation from production orders or manually via worker dialog.

Hands-free scanners

NIMMSTA HS50 (45 g) and ProGlove MARK Display. Hands-free scanning speeds up loading and unloading at the tugger train.

Expandable to a mixed fleet

Tugger train control as a standalone module or combined with the forklift guidance system and AGV control. FlexGuide4 is one system for all transport resources.

SAP Integration

Integrated directly 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. Confirmations and status updates flow back to the system in real time.

SAP PP & MM

Production supply by tugger train based on production orders. Material requests from MM trigger tours automatically.

SAP S/4HANA

Certified for S/4HANA. EvoBus (Daimler) already uses FlexGuide4 productively on S/4HANA, including tugger train control.

Frequently Asked Questions

FAQ: Tugger train control for SAP