Fraunhofer Institute for Material Flow and Logistics IML
Fraunhofer Institute for Material Flow and Logistics IML

Material flow planning & intralogistics planning

Content

Material flow planning and warehouse design form the basis of efficient warehousing and distribution systems. Balancing service levels, costs, and growth requires reliable data, clear objectives, and a realistic roadmap. We combine material flow analysis, layout planning, simulation, and IT integration into a transparent process – from brownfield sites to the construction of new logistics centers.

The Fraunhofer Institute for Material Flow and Logistics IML evaluates technical variants, quantifies investment and operating costs, and develops concrete measures. This results in scalable intralogistics processes with measurable effects.

Strategic framework for material flow planning and Warehouse Design

Material flow describes the physical and informational flow of goods and data. Precise planning considers the unity of processes, technology, logistics IT, and people; it determines capacities and defines interfaces.
Companies navigate volatile demand, numerous SKUs, space restrictions, and a shortage of skilled workers. CO2 targets and energy costs increase the pressure. Anyone planning to build a new warehouse or transform existing logistics must identify risks early on and ensure flexibility. Automation solutions increase performance, but require robust business cases, TCO/ROI calculations, and realistic ramp-up plans. A valid database on which to base material flow analyses is crucial.

That is why we digitize processes, create transparency, reduce distances and waiting times, and establish standard routines. In order to implement efficient and ergonomic systems, people and processes are at the core of our considerations. Fraunhofer IML works independently of manufacturers, translates research into practice, and delivers comprehensible decisions with clear KPIs. This gives you planning security and a precise path from concept to operation.

Service portfolio: Analysis, concept, tendering, implementation, operation

Our holistic approach covers all phases of your logistics project - structured, results-oriented, and tailored to your requirements.

  • Weakness and potential analysis along the material flow
  • Dimensioning, layout planning, variant comparison, and simulation
  • Technology scouting and automation solutions with TCO/ROI
  • Detailed planning, specifications, and tender support
  • Bid evaluation, award recommendation, and contract clarity
  • Implementation support, testing, acceptance, and ramp-up
  • Training concepts and change process support
  • Stabilization during operation and KPI-based monitoring
  • Sustainability, energy and space efficiency
  • Cardboard engineering and ergonomic workstations

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Methods and technologies

We start with a structured data set: master data, material flow data, inventories, and company-specific information. Motion mining and motion capture quantify manual work. From this, we derive a material flow analysis, identify bottlenecks, and model load assumptions. This results in a robust quantity structure from which a material flow diagram can be derived for further planning.

First, we create transparency about the automation market, compare possible solution variants—automatic small parts warehouses, shuttle systems, compact systems, AMR/AGVs, and sorter solutions—and evaluate them in terms of performance limits, redundancies, energy requirements, and safety concepts.

We use the insights gained to dimension picking, conveyor, and storage systems and to test scenarios using simulation.

A complete specification sheet defines KPIs, availability, and interfaces. Cardboard engineering accelerates iterations and improves ergonomics by simulating activities before the actual "go-live." On this basis, we drive process optimization, prioritize measures, and plan the ramp-up. The goal remains to optimize material flow with low risk and high transparency.


"Successful intralogistics arises when the processes are well designed as a foundation, resulting in seamless interaction between technologies, logistics IT, and people."
Dr. Veronika Kretschmer conducts research at Fraunhofer IML on human-centered work evaluation and design of logistics processes and heads the "Kompetenz Mensch" network..

Intralogistics planning: added value from concept to operation

Intralogistics planning has a direct impact on performance, costs, and resilience. A clear target vision structures processes, reduces distances, and shortens throughput times. An optimal warehouse layout improves picking performance and increases throughput. Neutral comparisons offers and precise specifications reduce implementation errors and deliver the best individual solution. We evaluate investments based on TCO and ROI and make assumptions transparent. Ergonomic workstations reduce cognitive and physical strain and stabilize intralogistics processes. In brownfield projects, we identify the best solution options and provide support in planning for safe implementation during ongoing operations.

When building a new warehouse, we create security and scalability early on. We anchor key figures, define clear responsibilities, and establish standards. After go-live, we accompany the ramp-up, measure target achievement, and continue to drive process optimization. This keeps technology, IT, and organization on track.

Quick Check Intralogistics: from findings to roadmap

The Quick Check provides a well-founded initial assessment in just a few weeks. 

  1. Information gathering: You provide the warehouse layout, material flow diagrams, KPIs, process descriptions, and information on technology and load carriers. Our team analyzes the documents and prepares for the on-site appointment.
  2. On-site analysis: Two experts inspect the premises, record processes, technology, and IT (e.g., using brown paper) and reflect on their initial findings in a feedback meeting.
  3. Knowledge transfer: We document potential and quick wins, prioritize measures in terms of time and topic, and translate them into a short roadmap. The result is a neutral recommendation for action with clear next steps.

The quick check is suitable for targeted assessments of individual areas or as a starting point for comprehensive projects - such as optimizing material flow or testing automation solutions.

Contact us now and request the quick check

Material flow planning: From specifications to acceptance

Precise specifications create clarity and comparability. We describe material flows, performance indicators, availability, interfaces, security, and IT requirements. In the tender process, we ensure fair comparisons, moderate bidder discussions, and check references. The evaluation and comparison of bids results in a well-founded award recommendation.

During implementation, we conduct design reviews, clarify interfaces between technology and IT, and accompany FAT/SAT and functional tests. We plan training concepts, prepare the ramp-up, and carry out structured acceptance tests. After go-live, we stabilize operations with KPI monitoring, clear communication, and a culture of feedback. Change process support and sustainability are incorporated into all phases. This ensures that the results of material flow planning remain effective throughout operations – measurable, robust, and scalable.

References

Greenfield planning

Concept and detailed planning of a new central warehouse: material flow planning, dimensioning, warehouse layout, and technical design; target processes, WMS/MFR specifications, tendering, and bid evaluation. Result: preferred solution and selection support for logistics service providers and technology.

Download Greenfield Planning PDF

Das Bild zeigt die Fördertechnik zur Anbindung des Wareneingangs, der Kommissionierplätze sowie der Verpackung.
© NORDWEST Handel AG

Brownfield simulation

Potential analysis of intralogistics and development of a consistent material flow simulation model; evaluation of measures by experiment. Result: proven combination of measures to achieve the desired increase in throughput.

Download PDF on brownfield simulation

Das Bild zeigt eine CAD Zeichnung zur Potentialanalyse
© Fraunhofer IML

Concept and detailed planning for distribution center

Validation of the existing concept and development of a comparative variant; dimensioning, material flow diagram, resource planning, and cost calculation.
Result: well-founded recommendation and detailed planning for a highly automated concept.

Concept and detailed planning - Download PDF

Das Bild zeigt ein Distributionszentrum
© Fraunhofer IML

Planning through to acceptance

Material flow analysis, variant comparison, and decision in favor of automatic tray storage including conveyor technology; tendering, specification support, preliminary/final acceptance, and availability tests. Result: Central warehouse implemented with guaranteed availability and stable ramp-up. 

From planning to acceptance - Download PDF

Das Bild zeigt Teile des Zentrallager mit abgesicherter Verfügbarkeit und stabilem Ramp‑up.
© q.cells GmbH

Quick Check Intralogistics

On-site analysis (quick scan), material and information flow assessment, catalog of potential; concept workshop with options for hall expansion and KO criteria evaluation. Result: prioritized measures and viable expansion option. 

Download PDF for Quick Check

Das Bild zeigt das Firmengebaüde des Unternehmens
© Arnold Lammering GmbH

FAQs on material flow and intralogistics

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  • The project duration depends largely on the scope, objectives, and availability of data. A compact quick check, for example to evaluate an existing logistics system or identify key optimization potential, can be completed within two to four weeks. This provides you with a well-founded initial assessment as a basis for deciding how to proceed.

    For more comprehensive planning projects—such as the design of a new logistics center, the planning of automation solutions, or the restructuring of existing processes—we typically work within a timeframe of 3 to 6 months. For particularly complex projects involving multiple stakeholders, extensive simulations, or integrative IT/ERP considerations, the project may take longer.

  • Accurate and complete data is essential for reliable planning. Before each project, specific data requirements are requested. These include article master data such as geometric dimensions, weights, or storage conditions of the product range, inventory data, order and goods receipt data, and warehouse or factory layouts. The raw data is used to create key figures and visualizations such as material flow diagrams or capacity and throughput analyses, which form the basis for subsequent technology selection and concept planning.

  • Ergonomics is an integral part of sustainable, human-centered intralogistics planning and serves to increase the efficiency, health, and safety of employees.

    How we integrate physical and cognitive ergonomics: We simulate work processes using approaches such as cardboard engineering. We evaluate these using Motion-Mining®, motion capture, and surveys to identify potential improvements in line with the STOP principle (substitution, technical and organizational measures, personal protective equipment). By reducing health risks for employees and increasing occupational safety and satisfaction, we strengthen the long-term resilience of an organization.

  • Our innovation transfer combines the latest research with your practical experience: We develop data-based, application-oriented solutions, increase planning reliability, and provide a basis for decision-making with clear KPIs. This gives you practical techniques with scientifically proven effectiveness.

  • Material flow planning designs the flow of goods, information, and load carriers within a location. It combines material flow analysis, warehouse layout, dimensioning, simulation, automation solutions, and IT architecture. The goal is to optimize material flow with clear KPIs, low risk, and sound investment decisions. Results are incorporated into specifications and implementation.

  • Material flow includes goods receipt, storage, replenishment, picking, consolidation, packaging, shipping, and returns. In addition, there is transport, conveyor systems, warehouse technology, inventory management, quality assurance, and control via logistics IT. The warehouse layout, defined intralogistics processes, and plans to digitize processes shape performance and stability.

  • A material flow concept describes the target vision for processes, warehouse layout, capacities, and technology. It considers automation solutions, evaluates TCO/ROI, defines KPIs, and outlines IT integration. The concept includes measures for process optimization and serves as the basis for the requirements specification and the optimization of material flow.

  • Proven methods include ABC/XYZ analyses, spaghetti diagrams, Sankey diagrams, time and motion studies, bottleneck analyses, and value stream analyses. In addition, the planning teams use discrete event simulation, motion- Mining® , motion capture, and process mining. Based on this data and KPIs, processes can be digitized, drivers of process optimization identified, and variants reliably compared.

  • Intralogistics encompasses all internal material and information flows between goods receipt and shipping.  Functional intralogistics are essential for efficient storage, transport, picking, and packaging. The associated IT rounds off the intralogistics system. Modern intralogistics processes use automation solutions and warehouse layout optimizations to reduce costs and ensure service levels.

  • The intralogistics concept combines the target vision, processes, layout, technology, and IT into a consistent plan. It sets the framework for performance and capacities, evaluates automation solutions, defines interfaces, and prioritizes measures. The result is optimized planning specifically tailored to the company and the basis for a roadmap with specifications for digitizing processes and gradually scaling operations.

  • Logistics planning analyzes data, designs processes, and dimensions facilities. It creates a warehouse layout, compares variants and performs simulations, calculates investments, creates specifications, and accompanies the tendering process. This applies to both existing projects and the construction of new logistics centers. The goal is to make robust decisions and achieve sustainable process optimization.

  • Master data, inventory data, transaction data, service levels, turnover rates, and inventories are essential. In addition, there are layouts, material flow diagrams, and process descriptions. We close data gaps, digitize processes, and thus ensure reliable material flow analysis and a robust warehouse layout.

  • Intralogistics solutions combine technology and IT for efficient warehouse processes. Examples: racking systems, conveyor technology, AS/RS, shuttle, AMR/AGV, sorter, WMS/WCS, and control stations. They aim to optimize material flow, reduce throughput times, and make processes scalable. Automation solutions and a suitable warehouse layout ensure performance and ergonomics.

  • When decisions are pending, budgets are tight, or there are competing options. The Quick Check identifies quick wins, prioritizes measures, and provides a neutral basis. This ranges from reviewing automation solutions to preparing specifications and optimizing material flow.

  • With clear requirements in the specifications, structured tendering, bid evaluation, and award recommendation. During implementation, we test, train teams, and stabilize intralogistics processes with KPI monitoring. This ensures that process optimization and technology work together while IT and organization remain aligned.

  • We start with analysis and a target vision. This is followed by concept variants and simulation. Based on the investment cost analysis and system efficiency, a decision is then made on the preferred variant. We then draw up the specifications, support the tendering process and implementation through to ramp-up. This applies to existing facilities as well as to the construction of a new logistics center – including process optimization.

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