Simulation with ipolog
Efficient material flow planning with simulation software
Display and optimize material flow with the ipolog simulation software
Why is material flow simulation so important?
Optimizing the flow of materials is a key factor for efficient logistics processes and economic success. In practice, however, this is often a complex process: production systems, transport routes, conveyor technology and storage areas have to be coordinated with each other.
Many companies still rely on Excel-based calculations or isolated planning tools such as CAD, Visio or PowerPoint. This leads to high coordination costs, inconsistent data and planning alternatives that are difficult to compare. At the same time, requirements are increasing:
- Regular delta evaluations and alternative scenarios must be carried out quickly.
- Several planners work in parallel and have difficulties keeping data synchronized.
- Material flows must be flexibly adapted if production quantities or premises change.
- Complex routes for tugger trains must be planned, evaluated and optimized.
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More InformationMaterial flow planning with the ipolog simulation software enables you to design precise and dynamic processes by easily testing and adapting different scenarios to minimize bottlenecks and inefficiencies and sustainably increase the efficiency of your logistics.
Read more here: How to optimize your material flow for better planning results
Typical mistakes in material flow planning in practice:
No matter how carefully you plan, avoidable mistakes happen again and again in practice. A classic example: an important Excel formula is accidentally deleted or overwritten during copying. Suddenly, incorrect calculations are made that only become apparent much later.
Or: Several planners work on the same file, but save different versions. Who has the latest version? The comparison costs valuable time – and in the end, plans are based on completely different assumptions.
This is where simulation-based material flow planning comes in: By using software such as ipolog, companies can visualize, analyse and optimize their material flows – even before changes are implemented in reality.
All data remains consistent, changes are automatically taken into account and visual analyses make planning errors immediately visible.
How exactly does this work? Here are the 10 steps you need to implement your planning in a structured and efficient way.
10 steps to a simulated material flow with ipolog
With ipolog, you can plan material flows in a structured way, analyze optimization potential and compare alternative scenarios – all in one integrated environment.
1. Determine the planning criteria
You determine the relevant parameters such as resources, processes, time modules (REFA, MTM), shift plans and production quantities and these are prepared in a standardized way in ipolog.
2. Visualize layout and route network
The layout with assembly stations, storage areas and logistics zones is created on the basis of your factory building. Transport routes and stopping points are defined. You can take into account your restrictions such as one-way streets, speed restrictions or the use of routes exclusively for selected resources.
3. Modeling transport processes
Material flows are mapped including means of transportation, process times and container types. Detailed planning at material level ensures precise space utilization.
4. Calculate resource requirements
In the next step, calculation methods are used to determine the resource requirements for the planning status based on the production quantities and the logistical quantity structure. The capacity utilization of each vehicle and employee can be visualized transparently.
5. Analyze planning results
- Heatmap: Bottlenecks on transport routes are made visible.
- Cost evaluation: Investment and operating costs per product or part are calculated.
- Area evaluation: utilization of storage and logistics areas and docks is checked.
6. Identify optimization potential
Based on the analysis results, underloaded or overloaded resources are identified. Bottlenecks in transport routes or unnecessary travel times can be selectively avoided.
7. Perform alternative planning
Planners can simulate various scenarios, e.g:
🔄 Adjustment of production quantities and cycle times
🔄 Comparison of tugger train, forklift or AGV supply concepts
🔄 Optimization of route guidance for better utilization of the individual routes or tugger train drivers.
8. Compare results
With the integrated KPI comparison, ipolog compares alternative plans. This allows you to quickly identify the best solutions or carry out delta evaluations for future demand developments.
9. Present results
In the ipolog Factory Viewer, plans can be visualized in a realistic 3D environment. Means of transportation move within the simulated hall so that processes can be tracked over time.
10. Making well-founded decisions
Thanks to transparent analyses and scenario comparisons, you can make the best decisions as early as the planning phase – and avoid expensive adjustments during subsequent operation.
Conclusion: Why simulation software is worth your investment
Simulation-based material flow planning with ipolog enables companies to identify optimization potential at an early stage, efficiently compare planning scenarios and flexibly adapt material flows.
📌 Fewer bottlenecks, lower logistics costs and more efficient processes – before changes become reality.
Would you like to find out whether ipolog can also optimize your material flow planning? Contact us for an individual consultation!