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The Ideal Tugger Train System with Intralogistics Software

Plan your tugger routes using sophisticated algorithms

The planning of tugger trains in intralogistics is often difficult due to a variety of factors. Creating a tugger train system includes designing on a resource basis while also weighing the advantages and disadvantages of a tugger train system. Our »ipolog software allows you to make concrete statements in both rough and detailed production planning. Learn more!

Would you like to plan and optimize your entire material flow – not only your tugger trains, but also resources such as AGVs, forklifts and staff?
Then read about the advantages »material flow planning with ipolog provides!

When are tugger trains useful and worth the investment? Find out with ipolog!

Particularly in the case of recurring transport tasks and long transport distances, tugger train systems are suitable for high-frequency delivery of a wide variety of containers in small batch sizes to different consumption points. ipolog software helps you correctly plan the intralogistics of these tugger routes.

The earliest and latest possible provision times are calculated backwards from the installation location based on real production program data. This ensures that the required material are provided at the right place and at the right time.

You can evaluate with ipolog whether using a tugger train system is advantageous and which resources are needed for the implementation. Simulate different scenarios and recognize temporary peak loads in the planning stage.

Depending on the planning phase (rough, detailed, serial) you can use ipolog to make key statements about the following target values:

Tugger train requirements

number of tractors, number of trailers on a type basis


precise statements about the required number of tugger train drivers and logistics staff

Tours per day

See the tours over time

Total route

Layout-based evaluation of individual routes

Process times

loading, driving and unloading in a Gantt diagram

Your planning: roughly sketched or detailed

During the rough planning stage, the calculation in ipolog is based on the Logistics Quantity Structure (LMG) and the standard process modules, which can be adapted to the respective situation. In detailed planning and operations, the concrete production program serves as the time basis for which staging times can be calculated. In earlier stages ipolog generates a synthetic demand program from the forecast production distribution. This allows you to use the same tool with a consistent data model throughout all phases and to »dynamically simulate your production logistics.

Planning in ipolog offers concrete possibilities for planning and optimizing tugger trains using a 3D model and detailed evaluation. The simulation has the advantage that activities such as loading, driving and unloading and the transports themselves can be traced in a tour Gantt over time.

In the animation and simulation of the tugger trains, they travel through the hall at the correct time in the 3D model on the basis of source-drain relationships. The displayed routes are not only visible in the 3D view. This means that all those involved in the decision-making process can find each other immediately and can discuss the represented situation together. Direct evaluation allows for the identification of specific bottlenecks and to develop and simulate optimal solutions in ipolog.

The density of the traffic volume in the facility can be dynamically displayed at any time in the form of a heat map. The more intense the coloring, the more vehicles are on the same route at that time. This allows for tugger route planning to be evaluated and adjusted if necessary. This immediate feedback accelerates planning and leads to reliable results.

Discover the added value of tugger train system planning!

Here is an overview of the advantages that can be achieved by using ipolog software:
  • Layout based

    Layout-based creation of tugger routes

  • Tugger train requirement

    Calculation of the tugger train requirement via defined material flow chains

  • Dynamic

    Dynamic route calculation of transport orders based on staging times

  • Order list

    Order list with earliest and latest delivery dates and source-drain relationships

  • Evaluation

    Analysis of tugger train planning over time with load peaks

Perfect planning with ipolog! Start your tugger train project now.

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