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The advantages of automated tugger train solutions

How you benefit from automated concepts

Trends like digital transformation and innovative processes such as lean production have turned production logistics into one of the fastest developing economic sectors. Automation solutions are playing an increasingly important role in meeting the requirements that are changing as a result. The key questions are: Is an automated tugger train worthwhile for my company? What are the benefits for me? Will the use of an automated tugger train let me reduce my costs for material transport and logistics?


The benefits at a glance

Automation solutions have already successfully proven their worth in numerous pilot projects. They have also highlighted a whole range of clear benefits:

  • Reduction of stock
  • Increase in delivery frequencies 
  • Goods tracking in real time 
  • Minimisation of incorrect processes
  • Space savings
  • Compensation for staff shortages
  • Financial benefits
  • Less strain on employees

1. Reduction of stock

The highly cyclical, synchronised supply with automated tugger trains enables the efficient provision of small batch sizes and a significant reduction in stock in the production area.

2. Increase in delivery frequencies

Automated tugger trains enable efficient production. Deliveries to the necessary locations occur just in time or just in sequence. The material flow is integrated into the demand situation on the production machinery with precise supply and removal from the machines.

3. Goods tracking in real time

Using warehouse management software to track goods in real time makes it possible to achieve significant gains in quality and efficiency while avoiding search times and errors.

4. Minimisation of incorrect processes

Small errors are often all that it takes to disrupt an entire process and therefore the flow of goods. The use of automated tugger trains with corresponding monitoring software helps the operator minimise the error rate.

5. Space savings

Space for industrial areas is becoming increasingly tight, while the size of operations is increasing. The goal is to achieve space-saving intralogistics. Automated processes in the warehouse allow the necessary operating widths for industrial trucks to be minimised. Mobile handover stations enable flexible handling during loading and unloading processes – even in the tightest of spaces.

6. Compensation for staff shortages

Staff shortages have also been a significant problem in intralogistics for many years, since filling vacant positions with qualified staff is a huge challenge. Automated or autonomous tugger trains can help overcome this deficit.

7. Financial benefits

Manual activities are reduced. By reducing the maintenance costs and levels of damage to trucks and machinery, as well as minimising accidents involving personal injury, it is possible to achieve a dramatic reduction in costs. This increases the predictability of expenses while reducing provisions for unscheduled maintenance measures.

8. Less strain on employees

People play a key role in the use of conventional tugger trains, as muscle power is required to load and unload the trolleys on the frame. An automatic tugger train solution that replaces strenuous manual processes (such as loading and unloading) provides genuine added value for employees. Employee productivity is increased as inefficient travel times are eliminated. Instead, value-adding activities are performed by the operator.

“Automatically unemployed?”

The topic of automation is an ominous prospect for many employees. However, the implementation of an automated tugger train system is not at all associated with job cuts – on the contrary, it actually helps employees by taking over manual processes and counteracting staff shortages in other areas.

Requirements analysis

Our offer for the joint preparation of the concept and requirements specification

We answer the following question together with you: What potential for automation can be uncovered in your warehouse and production logistics – and what does your automation system ultimately have to achieve?

Result: an individual requirements specification based on your needs, which you can use for your invitation to tender. The requirements specification is the technical basis for your automation concept.

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Motivation for procuring a driverless transport truck

The close connection between production and logistics, the constantly increasing staff shortage, the demand for flexible production processes and digital production and logistics has led to a boom in demand for driverless transport trucks in the past few years. Logistics is the cornerstone for ensuring smooth operations in production plants: the quick and reliable delivery of the required material to the relevant stage in the process chain allows time and the associated costs to be effectively minimised.

Here, the automation of the processes is key. Tugger train solutions, especially if they are automated, ensure high process efficiency and a reliable flow of goods. Planning for a tugger train system that meets your specific needs requires expertise in this field, as a range of factors need to be considered.

Return on investment (ROI)