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Planning and Optimization of the Material Flow Improve Productivity

You want to find out in which production areas you would be able to reduce cost without investing a lot?

Planning of the material flow organizes and optimizes the flow of materials within production processes with the goal of improving productivity. Material flow denotes the “structured and organized movement of products from point A to point B, over the entire production system while taking into account the economic efficiency”.

More efficient utilization of space, lower investment costs and further cost savings, e.g. human resources, are the results.

Material flow is a complex process within the production process and cannot be optimally controlled without planning.

Example: Optimization of material flow through a different set-up

MES has relocated a bubble wrap production line from France to Germany.

It was not possible to set up the crane system again due to local conditions. The material flow analysis indicated that using a crane to supply sleeves would result in a more efficient set-up and save costs. For this reason a new crane system was built over the largest section of the installation.

Result: Optimization of the material flow resulted in a more economical production flow while taking into account the local conditions.

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Thomas Steinwachs, Head of Service
Thomas Steinwachs
Head of Service
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Material flow planning: production line before relocation
MES planning of the material flow on the occasion of relocating a bubble wrap production line: production line before relocation.
material flow planning: production line after relocation
Production line after relocation. A more efficient set-up is achieved by utilizing a crane system to supply sleeves and costs are saved.

Reducing material flow costs means curbing overall production costs

Optimization of individual costs while accounting for production development.

The following factors are taken into account:

  • Storage costs
  • Costs for human resources
  • Costs for transport
  • Energy costs
  • Fire protection
  • Occupational safety and health
  • Environmental protection regulations

Great effect at little expense

The optimization of the material flow can be carried out in small steps, e.g. by:

  • Optimizing set-up times
  • Revising transport logistics
  • Combining installations

Material flow planning – three plant situations with different requirements

Project example: Planning the material flow of a plastics manufacturing facility

In fall 2004 MES GmbH was awarded the contract for planning the material flow of a plastics manufacturing facility. As a result of basic engineering procedures, the material flow within production and warehousing was optimized so that the planned construction of a new shop building was no longer necessary.

Result: Estimated investment costs of € 600,000 were avoided.

Thomas Steinwachs, Head of Service

Thomas Steinwachs
Head of Service

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