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Smart Material Flow – factory flow solutions for streamlined processes with reduced non-productive times

Up to 40% of resources are still being allocated to non-value-adding activities. There is a better way: you will optimize your shop floor with a transparent material flow. The foundation for this are unambiguous postings and digital mapping of your production. Discover modular solutions for a most efficient factory flow.

Reduce throughput times and part costs

You plan and control the production process systematically thanks to digital mapping of your production.

Great potential even for small production units

You streamline your production with an efficient factory flow – without a complex infrastructure.

Modular solutions pave the way for you

Suitable modules simplify your daily tasks in the factory flow.

Increased sales thanks to digitalized material flow

Transparency and improved processes harmonize all resources within the material flow.

Increased sales thanks to a digitalized material flow

Transparency and an improved factory flow increase your utilization overall. All machines, processes, sequences and personnel play a role in this. Coordinate it all with solutions from TRUMPF.

Hardware

Lay the foundation for your transparent material flow with non-automated and automated storage systems, storage areas, docking stations and AGVs (Automated Guided Vehicles) – in cooperation with manufacturers.

Software

In the office and mobile on the shop floor: use software to manage inventory and material flow, control transport efficiently and as an interface for automated guided vehicles.

Services

Appropriate to your company and project, we support you with analysis and simulation of your material flow, material flow consultation and planning, installation and commissioning of factory flow solutions and Initial Production Assistance.

Digitalize the material flow – create added value

To remain competitive in the long term, productivity and efficiency are important metrics on your shop floor. Unplanned additional effort interrupts the production flow and diminishes overall utilization. As a result, part costs soar and make it difficult for you to calculate reliably.

Increase of overall utilization, reduction of production costs

A digitalized material flow provides clarity in your factory flow. The basis: simple and unambiguous bookings combined with clearly defined storage locations. Apps and connected hardware minimize your work. This means that order and material flows are synchronized. The system adapts the transport sequence automatically when you change the production plan.

Make work easier for operators, reduce non-productive times

Tracking material movement digitally saves time and releases resources. You can use these resources directly for value-adding activities. Your factory flow will become even more efficient with our modular system comprising hardware and software: transport material and goods throughout your entire sheet metal process chain as autonomously as possible, from storage to delivery.

Control transport efficiently

You load machines coupled with a large-scale storage system fully automatically. But what do you do if there is no physical automation or direct storage connection? In these cases, you use a docking station and the Oseon transport guide system. As a central hub, the docking station registers the material movement automatically when parking or removing a pallet. Oseon either informs personnel on your shop floor when which order should be picked up, placed in intermediate storage or brought to the next workstation or it transfers this information directly to an automated guided vehicle.

Minimize the time and effort involved in bookings

The real time information concerning orders and material on the shop floor form the basis for an efficient production. TRUMPF systems automatically report this data, depending on the model and variant. Individual workstations – even external machines and manual operations – can be integrated in an intelligent material flow concept with Oseon and docking stations.

From manual bookings to a fully networked material flow

It's all about the optimum coordination of the order and material flows at every single workstation. Thanks to standardized processes, digital tools minimize the time and effort involved in bookings. What happens if you have to schedule in a rush job? No problem: manual intervention is possible at any time. Custom-fit software simplifies your working routine. Incidentally, you can also connect machines from different manufacturers thanks to open interfaces. Use the configuration stage suitable for your company:

1. Do you book orders and material movements manually on the tablet or using a manual scanner?

The Storemate function supports you on the shop floor for manual storage and logistic tasks. For example, it displays where which parts are stored and offers storage suggestions.

2. Do you plan, regulate and control non-automated transports on your shop floor?

The system automatically sends transport jobs to the operator
Docking stations support or replace your manual bookings
A mixed mode consisting of non-automated and automated transport is possible

3. Do you automatically record bookings at machines and docking stations, do AGV systems automatically take over the transportation?

The system sends transport orders to the AGV with integration with a small storage system (manual removal from storage)
Docking stations, TRUMPF machine tools and digitally connected workstations keep order and inventory information synchronized. This creates a continuous material flow
A mixed mode consisting of non-automated transport (personnel) and automated vehicles (AGV) is possible

Modular solutions pave the way for you

1 Connection with buffer storage

2 Integrate manual workstations

3 Integrate machines from any manufacturer in the material flow

4 Support of material deliveries to workplace groups

5 Material flow control

6 AGV connection

7 Automated material flow

8 Control system for non-automated transport

1. Connection with buffer storage

If there is no space in the subsequent station, the system automatically plans the transport of the material to a predefined buffer.

2. Integrate manual workstations

With the help of docking stations, you can integrate dispatch, assembly and quality inspections, for example, in the digitally optimized material flow. The docking stations are modularly structured and available in different variants, for example, as stations for the pallet cart or tracking station.

3. Integrate machines from any manufacturer in the material flow

Docking stations automate the material supply and disposal of all workstations on the shop floor.

4. Support of material deliveries to workplace groups

Production control and docking stations facilitate optimum working methods even for consolidated working areas.

5. Material flow control

The Oseon transport guide system is in charge of planning, control and management of the transports.

6. AGV connection

The openly designed AGV interface facilitates the control of non-automated transport as well as the simple and manufacturer-independent integration of automated guided vehicles.

7. Automated material flow

Docking stations automate material bookings and serve as a link between automated planning, AGV and human interaction.

8. Control system for non-automated transport

As well as fully automated transports via AGVs, the software can transfer instructions to personnel which then post the instructions directly on-site using a tablet.

Work flow as an example: no more parts / raw material in the machine

The work flow remains intact thanks to the integrated overview of the Smart Material Flow. Discover here how easily this factor flow solution works.

Docking stations: storage locations with added value

Docking stations are storage locations which are networked by sensors and which simplify your factory flow.

Your advantages:

detect the pallet ID and report the status back to the system
simplify delivery / collection of material
integrate any workstations, machines or storage locations in the automated material flow
are available in a modular format, for example as a pallet cart or tracking station

Autonomous material flow thanks to automated guided vehicles (AGV)

A self-organized material transport? What once sounded like science fiction just a few years ago is now becoming part of the daily routine in more and more production facilities. Automated guided vehicles (AGV) navigate the shop floor with pinpoint precision thanks to sensors. They load and unload machines in fully or partially automated processes and transport finished parts to dispatch.

Good to know: with Oseon, you can also control mobile units such as an AGV and can coordinate your entire factory flow in this way.

Good to know...

What is a factory flow?

The term "factory flow" denotes the in-house material and inventory flow: from the delivery of the material on the company property to production and storage to the point when the finished product leaves the building again.

Which functions does a factory flow fulfill?

The central task of the factory flow is the in-house flow of material. The material is delivered, runs through different production steps and is placed in intermediate storage. For dispatch, the products are no longer part of the factory flow and are transferred back to the external logistic processes.

How does an autonomous material flow work successfully?

Automation is the key to an autonomous material flow, also called factory flow 4.0. Manufacturing systems receive an order and independently request the necessary material. More and more, they coordinate their material supply directly with automated guided vehicles.

The success story of our customer Dax

"The material flow on the floor is working smoothly now." DAX is working more efficiently with TruTops Fab Logistics in combination with an automated guided vehicle system from Jungheinrich.

Read story

Smart Factory Consulting – let us advise you!

We will accompany you on your path into the connected future. What potential does networking have for you? What could your path to networked production look like? Regardless of whether you just want to make a start, gradually adapt or have a fully networked production, our consultants will help you find the ideal solution for any situation.

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