In use at EvoBus, Brose, and KNOLL
Their shuttle trains are running on schedule. But is this the best plan?
Fixed routes run even when there is no demand. FlexGuide4 calculates the route only when demand arises. Directly in SAP, and can be combined with forklifts and AGVs.
50 million+
Ride requests generated
Brose, 17+ locations worldwide
1.000
Trips per day
KNOLL, mixed fleet including 2 articulated buses
< 0.1%
Error rate
KNOLL, Forklifts + Automated Guided Vehicles (AGVs)
Why FlexGuide4
Route-Based Train Control That Thinks for Itself
Anyone who has ever seen a route train making an empty run will understand the problem. FlexGuide4 plans the route based on current demand.
Fully Dynamic Route Planning
Fixed, fully dynamic, or permanent routes. FlexGuide4 calculates the optimal route based on demand, distance, and time window. No more rigid schedules.
Trailer Management in SAP
Location, loading status, and contents of each trailer, in real time in SAP. B/C frames and picking coaches, stationary and mobile trailers, sorted and unsorted loads.
Compatible with mixed fleets
Control tugger trains, forklifts, and AGVs through a single system. KNOLL operates a fleet of 14 forklifts, 2 tugger trains, and 3 AGVs, with an error rate of less than 0.1%.
Cockpit & Visualization
Scheduled jobs, route status, and utilization—all displayed in real time in the cockpit. Driving assignments can be edited and prioritized directly.
Hands-Free Loading and Unloading
Route truck drivers work hands-free using handheld scanners (NIMMSTA HS50, ProGlove MARK Display). Faster scanning processes and fewer errors during loading and unloading.
Work Schedule Models & Breaks
Order scheduling takes into account work schedules, breaks, and planned times. Routes are planned realistically. No overloading, no idle time.
Here’s how it works
From Material Requests to Optimized Routes
1
A need arises
Material requirements from SAP (Production, Warehouse, Shipping) or via the worker dialog are fed into the central order pool.
2
Tour is being calculated
FlexGuide4 calculates the optimal route: distances, time windows, trailer capacity, and loading sequence—all in a fully dynamic manner.
3
Driver processes
The tour appears on the terminal. Hands-free scanning at each stop. Loading and unloading with barcode confirmation.
4
SAP has been notified
Every confirmation is sent back to SAP in real time. Cockpit displays progress, utilization, and key metrics.
References
Companies that use FlexGuide4 to control train sets
EvoBus (Daimler Truck)
Production Supply
Centralized Logistics Control for Conveyor Trains and Forklifts in Bus Production in Neu-Ulm. Demand-Driven Order Picking, Real-Time Control in SAP S/4HANA.
SAP S/4HANA Platform
Brose Automotive Parts
Global Rollout
17+ locations in 24 countries. AGVs, forklifts, and automated guided vehicles combined in a template-based approach. A new location will go live in a few days.
Over 50 million ride requests
KNOLL Mechanical Engineering
Mixed fleet
14 forklifts, 2 tugger trains, and 3 Safelog AGVs in a single fleet, all controlled by a single system. 1,000 transport orders per day with an error rate of less than 0.1%.
< 0.1% error rate
How many empty runs is your fleet currently making?
Brose manages more than 17 locations with a single system. KNOLL achieves an error rate of less than 0.1%. Talk to us about your potential.
Applications & Functions
More Than Just Route Planning
From the moment the materials are requested until the trailer is back in its place. Not a single step is missed.
Fixed, Dynamic, and Permanent Tours
Three tour models in one system. Fixed routes for consistent demand, fully dynamic routes for fluctuating demand, and permanent routes for long-distance runners.
Trailer Types & Load Capacities
Manage various types of trailers with different load capacities. Automatically reserve and assign them to the appropriate route.
Loading and Unloading Strategy
Sorted and unsorted loading strategies. FlexGuide4 takes loading and unloading operations into account as the route progresses.
Multi-stage transportation
Transfer between tugger trains and forklifts. Automatic generation of transport orders from production orders or manually via the operator interface.
Hands-Free Scanner
NIMMSTA HS50 (45 g) and ProGlove MARK Display. Hands-free scanning processes speed up loading and unloading at the tugger train.
Expandable to a mixed fleet
Route-based train control as a standalone module or combined with a forklift guidance system and AGV control. One system for all transport resources.
SAP Integration
Seamlessly integrated with SAP
FlexGuide4 is SAP-certified (S/4HANA) and integrates directly with your existing SAP modules.
SAP EWM & WM
Route order assignments directly from SAP Warehouse Management. Confirmations and status updates sent back to the system in real time.
SAP PP & MM
Production supply via material train based on production orders. Material requests from MM automatically trigger routes.
SAP S/4HANA
Certified for S/4HANA. EvoBus (Daimler) is already using FlexGuide4 in production on S/4HANA, including route train control.
Frequently Asked Questions
FAQ: Route Train Control for SAP
Book a Free Consultation
Ready to control your train sets intelligently?
Talk to our experts—with no obligation, for concrete advice tailored to your SAP environment.
Sascha Scherer
FlexGuide4 for worry-free intralogistics
phone: +49 931 466 211 100