Material flow control as a service for a distribution center
Material flow control, also material flow controller or material flow control system (MFCS), is very often referred to as an order management system directly assigned to materials handling equipment. However, this view does not do justice to the task if there is a heterogeneous structure of materials handling equipment in a logistics center that has grown over time, where optimum operating results can only be achieved through coordinated interplay.
The MFCS in the narrower sense fulfills a central function in the world of logistics center IT systems – to ensure the optimal throughput of the facility at all times. Its functions are used on the one hand by a facility that is generally optimized in terms of investment costs or a conglomerate of different facilities and expansion stages, and on the other hand by the operational functions with different usage strategies. The behavior of the MFCS must be predictable and stable and it must be possible to adapt it to new strategies, expanded facilities and new ideas at any time during runtime. In material flow control, this requires a standardized solution that is flexible enough to cope with all requirements or that can be easily adapted or expanded to meet new requirements.
Transport execution in material flow control
The primary task of the MFCS is to perform existing transport tasks generated by other systems in such a way that the facility is not obstructed. To do this, it must take into account the operating status of the facility and the occupancy status of routes, nodes as well as transport resources and assign the available materials handling equipment with the corresponding transport orders . It is not the task of the MFCS to carry out the transport orders itself, but that of the subordinate control systems. In particular, transport coordination must take into account the fact that the load situation of all conveying areas must be considered together. For example, the frequently encountered constellation of a forklift traffic area with a pallet conveyor system and an automatic high-bay warehouse must be controlled together.
Transport management in the material flow control system
The most important function of the MFCS is to assign materials handling systems with transport orders in a way that optimally utilizes the facility and best serves the logistical processes. Both objectives cannot be achieved independently of each other, and sometimes conflicting objectives arise. The logistical process always leads the way: the timely and complete delivery of inventory is the primary goal that must guide both the design of the facility and its operation. The optimal utilization of the facility by the MFCS is subordinate to this goal. It becomes clear that transport management is the central instance for monitoring, commissioning and coordinating all transport orders and transport resources.
Methods for creating optimal transport orders
What good is the best routing if there are no orders that can be planned? Derived from practical experience, the following methods are suitable for creating optimal transport orders:
- Listening in on the order pot -> trigger replenishment at an early stage and “forward” to the MFCS
- Batch picking -> gathering customer orders, multiple access to one article
- Time slice formation -> on-time route provision in goods issue (see also: cut-off time)
- Reservation of express batches -> time-controlled insertion into the daily routine
Further information on material flow control can be found under “The data basis of material flow control”.