Digital Transport Systems | Optimize Intralogistics with Digital Software Solutions

Digitalization in warehouse management, automated transport systems, mobile software solutions, ever-increasing competition in the market, and changing customer requirements—progress and digitalization are also reshaping intralogistics processes. Fortunately, there are various solutions to help companies make their own processes future-proof and successfully optimize intralogistics with digital transport systems.

Optimize your material flow with a digital transport system

Companies handle numerous movements of goods on a daily basis: Items are transported to an often-interim storage area, picked for specific orders, and processed in production. Goods are withdrawn from the warehouse, readied in goods issue, packed, and dispatched. It may sound simple, but in reality, it is fraught with challenges: A lack of transparency, search and route times for warehouse personnel, and even staff shortages make it difficult to ensure smooth internal material transport.

How can you overcome these challenges? One way is to use a digital transport system that is designed to realize transparent and reliable material flow. A forklift guidance system or an automated guided vehicle system helps you to optimally map your individual material flow and ultimately achieve efficient warehouse and production processes.

Forklift guidance system (FGS)
Independent, flexible, and route-optimized control of forklift fleets

Fewer or even zero empty runs, minimal idle time for forklifts, and a huge reduction in search times and incorrect loading. These are the biggest challenges that a forklift guidance system can help you overcome. With the L-mobile FGS, we address precisely these challenges and, with a flexible and precise forklift tracking system, we not only enable greater transparency, but also greater efficiency in your warehouse processes.

More information
Automated guided vehicle system (AGV system)
Flexible, reliable, and safe: Automated material flow with AGV systems

Automated guided vehicle systems are becoming increasingly popular. Floor-bound conveyor systems are used, for example, in production environments, logistics centers, and in the healthcare sector to ensure the smooth, transparent, and continuous flow of materials. Whether plastic containers, pallets, heavy or hazardous goods, the right AGV system can be used to reliably map a wide range of applications and requirements.

More information

Conveyor technology and digital transport systems: The basis for optimized processes in intralogistics

Using a suitable transport system is key when it comes to keeping your own intralogistics competitive, now and in the future. Digital transport systems or even automated transport systems, such as AGV systems, can offer significant advantages these days.

What does intralogistics actually mean? Definition and scope of internal material flow

Intralogistics originated back in 2004 when the “Forum Intralogistics”, an initiative of the VDMA (German Mechanical Engineering Industry Association), decided that a term was needed to describe the internal flow of materials within a company because the term “logistics” generally only refers to the transport of goods outside a company. So the term “intralogistics” was coined and defined by the VDMA as follows:

“Intralogistics encompasses the organization, control, execution, and optimization of the internal material flow, the flow of information, and the handling of goods in industry, trade, and public institutions.” – Source: vdma.org

This means that intralogistics includes all internal company processes that are related to procedures and tasks in material flow, logistics, production, and the transportation of goods and are carried out on the company’s premises. It is also often referred to as internal material flow or internal company logistics. Since intralogistics deals with the internal control of all processes related to the movement of goods, it includes not only goods receipt and issue, but also order picking, warehouse management, and all transport systems that are used internally for intralogistics. The key tasks are as follows:

Comprehensive (process) planning of the solutions used for handling the movement of goods
Optimizing machines and process control
Continuously optimizing and automating the conveyor technology and conveyor systems within the warehouse and internal material flow in the best possible way
Efficiently implementing internal projects within the aforementioned processes

Particularly for companies in the manufacturing industry, intralogistics is a central component of company processes. This is because the internal flow of materials never stops, as materials are often purchased, stored, processed, and dispatched again on a continuous basis. As a sub-area of logistics, intralogistics in this case includes the company’s production logistics, warehouse logistics, packaging logistics, and distribution logistics—in other words, all areas of logistics in which the material flow within the company must be taken into account.

Good to know: The difference between intralogistics and logistics

While intralogistics focuses on ensuring smooth internal material flow and its control, implementation, and planning, logistics goes a step further. It deals with the planning, coordination, realization, and control of the flow of information and goods not only internally, but also across companies in order to ensure the optimal supply of resources. Logistics is about getting the right goods, in the right quantity, in the right condition, at the right place, at the right time, to the right customer, at the right price. This philosophy is also known as the 7 Rs of logistics.

This shows that logistics is an extremely complex business area that consists of several sub-areas, including intralogistics. Other important sub-areas of logistics include procurement logistics, distribution logistics, warehouse logistics, and disposal logistics.

Production logistics is also one of the most important areas of logistics. It is often equated with intralogistics, but there is a small but subtle difference between the two terms: If a company only has one production site, the terms “production logistics” and “intralogistics” can both be used. However, as soon as several production sites are involved, “production logistics” also refers to inter-company logistics within production, i.e., also to transportation outside the company. Meanwhile, “intralogistics” still covers the internal material flow.

More information

Challenges of modern intralogistics

With advancing digitalization and ever-increasing global competition, many companies are constantly facing new challenges in intralogistics in order to meet growing demands. Increasingly, companies are realizing that existing processes within intralogistics are outdated and need to be optimized in order to keep up with the competition, now and in the future. One of the biggest problems is the lack of transparency.

In many cases, the movement of goods within material flow is still being recorded manually by warehouse personnel in the ERP system, after the goods have been moved, using a printed transport order or a handwritten list. Processing orders on the fly, without any documentation, is also not uncommon. However, manual entry and paper-based processes both present a high risk. Documents are lost, quickly scribbled notes are illegible and misinterpreted, and there is a high error rate when recording stock transfers that may have taken place hours ago. The result: The wrong goods in the wrong place, a lot of empty runs for forklift drivers in the warehouse, long search times for warehouse personnel, and unnecessary costs for the company—to name just a few of the problems.

The wide range of load carriers and loads that need to be transported in a variety of industries and companies is a major challenge. Due to the large number of load carriers that can be used in a company, and the fact that routes are always prescribed for optimized material flow, complex processes arise in logistics, making their implementation a difficult and lengthy task. Seamless and smooth cooperation between all entities involved in such a process is essential for successful intralogistics. This also applies to the digitalization and automation of processes.

Companies that still employ a rigid and conservative approach to the warehousing of goods, stock transfer, and dispatch will find it increasingly difficult to survive in the global market. This is because more and more companies are turning to digital and automated transport systems, such as forklift guidance systems (FGS) or automated guided vehicle systems (AGV systems) supported by reliable and digital warehouse management solutions. In addition, yard management is often used as a digital solution for loading and unloading trucks, thus linking intralogistics and external logistics.

More information

What is a transport system?

Companies that are considering implementing a transport system are initially faced with the issue of determining what form an optimal material flow solution might take. This provides the basis for deciding on the appropriate means of conveyance and the suitable transport system. While “means of conveyance” refers only to the actual means of transportation, e.g., a forklift or pallet truck, the transport system encompasses the entirety of the transport vehicles or transport technologies for the physical transportation of goods, as well as a software solution that can be used to control the system digitally and collect information. In an industrial context, a transport system can therefore be used to implement all internal transport operations—from transporting goods and merchandise to transporting people. This makes transportation one of the three most important processes in intralogistics, alongside storage and handling.

The purpose of a transport system in intralogistics is self-explanatory: it is to transport goods, such as pallets, boxes, or containers, within a company to the right place at the right time. Depending on the circumstances and requirements of a company, these transport operations are carried out either automatically or manually by continuous or non-continuous conveyors. Thanks to the modern software solutions and means of transportation available on the market, processes in intralogistics can now be customized. In this context, aspects such as automation, a high degree of flexibility, and the smart, route-optimized control of the means of conveyance are the key to remaining competitive as a company.

The tasks of a transport system: The control center for your intralogistics

digitalisierte Intralogistik_Stapler_Transportsysteme_SLS

To ensure that transport orders can be processed efficiently and that the necessary resources are always available, all the important information can be consolidated in a transport system. This allows forklift fleets, automated guided vehicle systems, and other resources to be controlled centrally.

How many forklift drivers are currently on duty and who is located near the next transport order? How does the forklift get to its destination via an optimized route? Where are the goods for the next order? These questions can be answered, for example, with the help of a forklift guidance system. Furthermore, the transport system, in combination with a mobile warehouse management solution such as L-mobile warehouse, ensures that all information relating to the process is recorded centrally. This means that it is always possible to see which items of a transport order have already been transported by the forklift driver or by an automated guided vehicle system.

More information

Successful transport management: Transport systems commonly used in intralogistics

FGS AGV system Tugger train Yard
management

Previous Next

Forklift guidance system (FGS)

By using a forklift guidance system (FGS), also referred to as a transportation management system, companies are able to manage their forklifts and industrial trucks at the warehouse or production site. The goal: Using route optimization based on tracking technology to prevent empty runs and forklift idle time and avoid search times in the warehouse as well as incorrect loading at the truck.

A forklift guidance system is suitable for use in large outdoor storage areas with GPS outdoor tracking, as well as for indoor warehouse management using UWB or RFID technology for tracking. Transportation management systems often offer the option of connection or direct ERP integration and can thus be seamlessly integrated with existing processes. Forklift drivers are also much better integrated in warehouse processes with a forklift guidance system. Thanks to a terminal mounted on the forklift, they receive information from the ERP system for the current order—and can even see forklift movements on a digital map. The result: A huge increase in transparency within processes.

A forklift guidance system gives the use of forklifts a distinct advantage over automated yet rigid conveyor systems such as roller conveyors or assembly lines. In addition to providing a high degree of flexibility, forklift operations can also be route-optimized, saving time and money.

More information

Automated guided vehicle system (AGV system)

While forklifts, pallet trucks, and the like usually still have to be steered through the warehouse by an employee, automated guided vehicle systems are already one step ahead here. As the name suggests, these are a means of transportation that work without being operated or controlled by a human and have their own drive unit. This means that the vehicles can move automatically and independently to transport material through the warehouse and production. An automated guided vehicle system usually consists of the following components:

One or more automated guided vehicles (AGVs) that transport goods within the company
A control system for the automated guided vehicles (AGVs)

Infrastructure such as charging stations, mechanical interfaces at the transfer stations, battery systems, or safety systems
Software and hardware to precisely locate vehicles and to transfer data between the AGV system and other systems

The movements of the means of transportation are controlled by a form of guidance. This can be markings on the floor, rails, magnets or transponders, GPS signals, lasers, or other possible navigation systems. Which type of track guidance is used for an AGV system depends on the circumstances and requirements of the company. In general, automated guided vehicle systems are mainly used in the automotive industry and the food and beverage industry, but they are also used in pharmaceutical manufacturing and in companies in the chemical industry to support intralogistics.

More information

How to successfully introduce automated guided vehicle systems

L-mobile whitepaper for direct download

Recognize and master challenges in material flow
The challenges companies face in intralogistics.
What is an automated guided vehicle system?
The components of an automated guided vehicle system and how they interact to achieve efficient material flow.
5 tips for the successful implementation of an automated guided vehicle system
We will show you what you should consider when planning and integrating your automated guided vehicle system.

L-mobile digital warehouse management – AGV system whitepaper: How to successfully introduce automated guided vehicle systems

Download the whitepaper now

Tugger train control

With a digital system for tugger train control, material supply within internal material flow can be planned, controlled, and implemented dynamically and automatically using tugger trains. To do this, the transport system takes over the planning of routes and schedules, taking into account a wide range of factors such as optimal capacity utilization or break times.

A tugger train is typically used in intralogistics when processes are standardized and can therefore be easily planned. It consists of a towing vehicle that moves one or more trolleys through the company’s premises. These trolleys are used for ground-level material transport from the warehouse to the production location. Tugger trains, also known as logistics trains, and a tugger train control system are particularly common in companies that supply their production just-in-time with materials from the warehouse.

Tugger train control ensures that the movement of trains through the facility is route-optimized, always choosing the most efficient transport route and reducing empty runs. There are three different ways of executing the routes or transport:

Permanent tugger train control
As soon as one route has been completed, the next route is immediately started.
Capacity-oriented tugger train control
The transport system has a predefined maximum capacity for the tugger trains. The system only initiates the next route when this has been reached. If the maximum capacity is not reached, a new transport can also be initiated between two routes when a fixed time period has elapsed.
Scheduled tugger train control
All tugger trains start at fixed times according to a schedule.

Yard management system

Yard management involves the control and coordination of all processes and tasks related to external vehicles on the company’s premises. These processes range from registering a truck at the entrance to the premises, loading and unloading vehicles at the loading ramp, right through to exiting the premises. The objectives of a yard management system include:

Optimizing logistics processes
Ensuring fast and efficient loading processes
Reducing truck waiting times
Increasing transparency for all site traffic

To achieve these objectives, the transport system basically ensures that the right trucks can be at the right loading ramp at the right time. The system optimizes the entry and exit control of vehicles, thereby ensuring a faster handling speed. In particular, companies that have a very large site with numerous loading bays and a high volume of delivery traffic can benefit from using a yard management system.

Mobile warehouse management solution as the basis for efficient transport systems in intralogistics

When it comes to intralogistics and warehouse management, companies face significant challenges. However, transport systems are not the only way to reap huge benefits. Introducing mobile warehouse management software and a warehouse management solution can also go a long way to achieving digital warehouse management and transparent processes. With L-mobile WMS and L-mobile warehouse, you have two mobile solutions for warehouse management that can be easily connected and integrated with our L-mobile forklift guidance system (FGS), automated guided vehicle systems (AGV systems), and other solutions.

L-mobile digital warehouse management warehouse ready for SAP Business One — warehouse ready for SAP Business One

L-mobile warehouse ready for Microsoft Dynamics Mobile warehouse management for NAV and Business Central — warehouse ready for MS Dynamics

Forklift guidance system, automated guided vehicle system, or even a conveyor belt—the right transport system for your company

To ensure you select the ideal transport system for optimizing your intralogistics, it is important to first have a clear idea of the requirements in your company. In addition, certain criteria and characteristics of existing warehouse processes and production processes that are already established in your internal material flow should be taken into account:

The transport area
For example, how much space is available in the warehouse? Does the material need to be transported at ground level (floor-bound) or overhead?
The transport goods
What goods need to be conveyed? Is the transport system mainly going to be used for bulk goods or piece goods?
The transport direction
How should the transport goods be moved? Will it be horizontal transport, e.g., between rack aisles, or vertical transport in a high rack warehouse? Are there any specific factors that need to be considered, e.g., inclines?
The conveyor technology
Should the intralogistics processes that need to be optimized be automated, e.g., using roller conveyors, or implemented manually with non-continuous conveyors such as forklifts?
The material flow process
Does the transport system have to be in permanent operation? Are the goods always transported at the same intervals and on the same routes? Do floor-bound transport systems require guidance by rails, magnets, or similar?

Previous Next

Based on your answers to the questions above, you can already narrow down the range of possible transport systems. Once you have defined your goals and completed the analysis, it is time to look for an expert partner to help you implement your transport system. Our team at L-mobile, for example, has years of experience in process optimization for intralogistics and is also well equipped to assist with forklift guidance systems and automated guided vehicle systems. With the expertise and experience of a partner like this, you can assess the feasibility of your planned project. Once all the necessary preparations have been made and the requirements have been clearly communicated to the partner, the next step is to work together to develop the project and make your vision of optimized intralogistics a reality.

Are you looking for the perfect partner to optimize warehouse processes, implement a forklift guidance system, or explore the possibilities of an automated guided vehicle system? Simply contact us and together we will develop the ideal solution for digitalizing and optimizing your processes.

Advantages of a transport system

Optimized transport routes within the company

Save transport and personnel costs

Empty runs and idle times are reduced

Reduced throughput times

Efficient fleet utilization

Increased stock transparency

Increased productivity in the warehouse, production, and dispatch

Optimized use of space with vertical conveyor technology solutions

Automated material flow possible

Lower error rate, e.g., due to fewer instances of incorrect loading

Optimal resource utilization

Integration with existing processes possible

What is conveyor technology?

The task of conveyor technology or conveyor systems is to transport all goods within a company from A to B using various methods and technologies. In other words, it is primarily about the means of conveyance employed. But the design and control of processes are also part of the scope of conveyor technology. Thanks to the wide range of conveyor technology, goods can be transported in any direction and over any distance within a company.

Conveyor technology therefore helps to optimize internal material flow by transporting goods in all areas of the process chain efficiently and error-free—thus making it an important part of intralogistics. The use of conveyor systems serves various purposes in intralogistics:

Better use of space, for example by using goods elevators to ensure that transport is distributed over several levels
Faster order picking
Idle times in material flow reduced or ideally eliminated, for example through automated transport systems
Improved adherence to schedules, which guarantees that goods are in the right place at the right time

The different types of conveyor technology used in intralogistics

Over the years, many different ways of transporting goods have emerged that can support companies in intralogistics. These technologies are divided into manual conveyor technology and semi-automated or automated conveyor technology.

Previous Next

Manual conveyor technology

Roller conveyors and conveyor belts in manual conveyor technology enable companies to transport goods in internal material flow to the desired destination efficiently, quickly, and without interruption. Once they have been placed on a roller conveyor, goods can be transported over any distance. Manual conveyor technology can also easily cope with differences in height. Manual conveyors are primarily used in dispatch or in order picking. One example of manual conveyor technology that will certainly be familiar to everyone is the baggage carousel at the airport, which transports passenger luggage.

Manual conveyor technology is primarily used for the simple and one-time transportation of goods. This usually involves roller, chain, or belt conveyors. These are conveyor lines that enable the direct linking of points, e.g., machines, by means of conveyor belts, electric floor conveyors, electric monorail systems, automated guided vehicles, and other conveyors.

Semi-automated and automated conveyor technology

Semi-automated and fully automated conveyor technology is becoming increasingly popular in intralogistics. This includes forklift guidance systems, automated guided vehicle systems (AGV systems), loading systems, lifting stations, or lifting platforms. Some of these transport systems contain elements that often still have to be controlled by humans, such as the forklifts within a forklift guidance system. However, technologies such as automated guided vehicle systems in particular show that the complete automation of transportation is also possible.

In addition to significantly greater flexibility compared to manual conveyor technology, semi-automated and automated conveyor technology is particularly impressive due to its high economic efficiency. The systems can be planned and designed individually based on the company’s requirements. Aspects such as the dimensions of the goods to be transported or their weight are taken into account.

Continuous and non-continuous conveyors: Internal transport systems and successful conveyor technology in intralogistics

Conveyor technology is not only divided into manual and automated transport systems. The means of transportation used can also be divided into two different categories: continuous conveyors and non-continuous conveyors. The main consideration here is how frequently and regularly goods have to be transported within the company.

Continuous
conveyors Non-continuous
conveyors

Previous Next

Continuous transportation of goods with continuous conveyors

If continuous conveyors are used in intralogistics, then the means of transportation or conveyance is used continuously and without interruption to transport goods. As continuous conveyors are constantly active, there is no need for manual control by employees—goods are moved from A to B automatically. This conveyor technology results in low throughput times, i.e., large quantities can be transported in a very short time. Internal transport systems for continuous conveyors include all types of roller conveyors and conveyor belts. Roller conveyors in particular are certainly among the most commonly used continuous conveyors. A distinction is made between:

Light-duty roller conveyors

… for transporting lighter goods.

Heavy-duty roller conveyors

… which are mainly used to transport heavy goods.

Small roller conveyors

… for companies that transport small load carriers, packages, or similar means of transportation.

Scissor roller conveyors

… flexible conveyor lines that can be custom configured (height, length, curves).

Continuous conveyors such as roller conveyors are particularly suitable for use in companies where the continuous transportation of materials on fixed transport routes is required. However, this reveals one drawback of continuous conveyors: They are rather inflexible. If there are many different and varying transport routes within intralogistics, non-continuous conveyors may be the more efficient choice, depending on the desired system requirements, of course.

Here are some other continuous conveyors that can be used in intralogistics in addition to conveyor belts and roller conveyors:

Chain conveyors

During transportation, the material is conveyed using chains, which are usually driven by a motor that can also be used to control the speed of the chain conveyor systems.

Circulating conveyors

Circulating conveyors can be used both as overhead conveyors and ground-level conveyors. Circulating conveyors are particularly suitable for transporting piece goods at a constant speed. A distinction is made between conventional circulating conveyors, in which goods are attached directly to the chain, and Power & Free systems, in which a two-rail system is used and goods do not have to be attached directly to the chain. In this case, the chain still runs continuously.

Pneumatic conveyor systems

This transport system is primarily used to move bulk goods through pipes with the aid of air.

Hydraulic conveyor systems

Goods are moved through pipes with the aid of liquids, usually water.

Flexible transportation of goods with non-continuous conveyors

The internal transport systems used in intralogistics also include non-continuous conveyors. In contrast to continuous conveyors, non-continuous conveyors are only used when goods actually need to be transported. Accordingly, the transport systems in this case are not permanently installed and automated conveyor belts, but rather a location-independent means of transportation, such as forklifts or cranes. In many cases, control by humans is a prerequisite for the use of non-continuous conveyors. However, automated non-continuous conveyors, such as an automated guided vehicle system (AGV system), are already being successfully used.

Non-continuous conveyors have a decisive advantage: They are extremely flexible and can, in theory, be used anywhere within the company. Non-continuous conveyors can be a great support, especially in companies where the internal material flow is not defined by fixed routes and goods that need to be transported continuously. However, manually controlled means of transportation also have some disadvantages. For one thing, they can lead to longer idle times. Transportation comes to a temporary standstill, especially when loading and unloading means of transportation. Secondly, non-continuous conveyors often lead to higher operating costs. For example, a forklift must be controlled by a forklift driver, while an automated conveyor belt works without human interaction. There are a large number of non-continuous conveyors, so they are divided into different categories:

Overhead transport systems

Overhead non-continuous conveyors include cranes, for example. They transport suspended goods through the air.

Floor-bound transport systems

Goods are transported by conveyors that run on the ground and are bound to the floor, so to speak. They include forklifts, pallet trucks, and hand trucks. They are classic examples of non-continuous conveyors and are also referred to as industrial trucks. As a rule, industrial trucks are not attached to rails, but can move freely and flexibly.

Rail-bound transport systems

A means of conveyance where goods are transported on rails following a predefined transport route. These can include rail-mounted trucks, for example.

Stationary transport systems

This means of conveyance is tied to a fixed location where goods are transported. Examples of these systems include elevators and lifting platforms.

Visit our online events and experience digital transport systems live

Events

Digital Transport Systems | Optimize Intralogistics with Digital Software Solutions

Optimize your material flow with a digital transport system

Conveyor technology and digital transport systems: The basis for optimized processes in intralogistics

What does intralogistics actually mean? Definition and scope of internal material flow

Good to know: The difference between intralogistics and logistics

Challenges of modern intralogistics

What is a transport system?

The tasks of a transport system: The control center for your intralogistics

Successful transport management: Transport systems commonly used in intralogistics

Forklift guidance system (FGS)

Automated guided vehicle system (AGV system)

How to successfully introduce automated guided vehicle systems

Tugger train control

Yard management system

Mobile warehouse management solution as the basis for efficient transport systems in intralogistics

warehouse ready for SAP Business One

warehouse ready for MS Dynamics

Forklift guidance system, automated guided vehicle system, or even a conveyor belt—the right transport system for your company

Advantages of a transport system

Optimized transport routes within the company

Save transport and personnel costs

Empty runs and idle times are reduced

Reduced throughput times

Efficient fleet utilization

Increased stock transparency

Increased productivity in the warehouse, production, and dispatch

Optimized use of space with vertical conveyor technology solutions

Automated material flow possible

Lower error rate, e.g., due to fewer instances of incorrect loading

Optimal resource utilization

Integration with existing processes possible

What is conveyor technology?

The different types of conveyor technology used in intralogistics

Manual conveyor technology

Semi-automated and automated conveyor technology

Continuous and non-continuous conveyors: Internal transport systems and successful conveyor technology in intralogistics

Continuous transportation of goods with continuous conveyors

Flexible transportation of goods with non-continuous conveyors

Visit our online events and experience digital transport systems live