Logistics planning / intralogistics

Logistics planning / intralogistics

Optimal logistics solutions in Greenfield and Brownfield

Planning of intralogistics solutions

The optimal design of material flow, process planning and system selection creates the added value that our consultants generate in logistics planning.

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Dr. Udo Riedesel

Dr. Udo Riedesel Head of Logistics

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  • Consulting and planning of intralogistics
  • Logistics planning for Greenfield and Brownfield
  • Material flow, processes and system selection
  • Logistics strategy and order picking strategy
  • Layout planning and calculation


Optimal logistics solutions in Greenfield and Brownfield

Your advantage: Our approach has proven itself a hundred times, experience and benchmarks are available for all size classes of logistics projects.

Arguments for logistics planning from agiplan

  • Sound derivation of system selection from process analysis and material flow planning
  • Many years of experience of our project engineers with projects of all sizes in numerous industries
  • Comparative values and benchmarks
  • Consideration of state of the art storage and conveyor technology
  • Demand-driven automation
  • Design and implementation of Warehouse Management System (WMS) in an ERP Environment

With the following planning steps we achieve an optimal result:

Basis of planning = analysis of premises and basic data

The better the basics of logistics planning in intralogistics, the better the result. In order to guarantee the highest possible performance and future-proofing of the new logistics centre or existing logistics system, agiplan's logistics planners attach great importance to determining the fundamentals of all logistics processes.

On the one hand, these include the specific premises of the investing company and future operator (e. g. basic building conditions, planning horizon, turnover, product range, order structure, working hours, stock, peak load factor, etc.)

On the other hand, the basic data that forms a reliable calculation of process planning and system design.

Basic data include Article structure (e. g. EAN, SKU, dimensions, weight, volume, stacking factor), Load Carrier data (e. g. Categories, quantitiy, dimensions, average fill levels, quantity per LC), movement data in the warehouse (e. g. accesses, part types, response times, goods receipt/goods issue), stock (e. g. shelf life) and order structure (Quantity, items per order, order type).

The data is checked for plausibility and completeness, analysed (ABC/XYZ analysis) and prepared for further logistics planning. If data is missing or of insufficient quality, agiplan can usually carry out an experience-based assessment and supplementation without the planning process stalling.

Based on the basics, agiplan develops the material flow, defines processes and functions (incl. the picking strategy) and chooses the storage and picking systems, taking into account the warehouse management system (WMS).

Core of the planning: Material flow, processes, system selection

Material flow planning, process planning and functional description as well as system selection are at the heart of the planning process. Here, the support of an experienced logistics planner brings the most obvious added value.

This part of logistics planning requires experience with comparable tasks, system thinking in order to handle complexity safely, creativity for finding the best individual solution and a competent, manufacturer-independent overview of current technical logistics systems and their performance.

Material flow

The movement data from the basics is quantified in an actual material flow chart, subdivided into goods receipt and goods issued.

Development scenarios and the scalability of the warehouse are being considered. A material flow diagram is generated, which maps the relationship between source and sink, volume flows and dynamics of the entire system in the target state. Depending on the application, a simulation (MFS - material flow simulation) can supplement this step.

Processes and functions

In process planning, individual workflows and transport chains are defined, e. g. warehouse systems, picking strategy and sequences, sorting systems, packaging, goods issue and transport systems.

System selection

The logistics system planning and system selection includes the comparison of systems and the dimensioning (power, area capacity, storage spaces etc.) of order picking systems, storage systems and other subsystems.

Typically, this raises the question of the degree of automation (semi-automatic, automatic or manual picking) taking into account scalability, employee flexibility and adaptability. Our logistics specialists ensure that the right system solution is found for your project.

Subsequent to the conception phase, further planning steps are elaborated:

Personnel calculation

Based on the conceptual design, the demand for personnel (FTE = Full Time Equivalent) for intralogistics is determined depending on the distribution time factor of the operator. The cost estimate is separated for each process and function. The RTD positions required at the end of the planning horizon are determined using benchmarks and empirical values.

Layout basics

A basic layout derived from the system selection and personnel calculation determines roughly the area required for the project in square metres. This is made up of the areas for operating equipment, storage areas, transport and traffic areas, auxiliary areas as well as administrative and social areas and is supplemented by a surcharge factor.

Ideal layout planning

During structural planning, the functional areas are arranged in a space-saving and optimal way. The aim is to achieve a minimum number of transports with maximum space utilization and expandability. The result is an ideal layout that takes into account the material flows with an optimal arrangement of the functional areas.

Depending on whether the planning takes place in the greenfield or brownfield, different arrangement principles are available for the material flows. The most common variants are the I-flow, L-flow and U-flow.

Layout planning (block layout)

In this step, a real layout is created from the ideal layout. The layout is arranged on the possible property or in the existing building. Several solution variants are created. On the basis of a utility value analysis with weighted criteria, the variants are evaluated and the preferred variant is determined. This is one is then to be planned in more detail.

Investment and operating costs

A profitability comparison of the logistics system based on investment cost accounting is calculated for each variant of logistics planning. The preferred solution from the layout planning is calculated in detail, taking into account the operating costs.

The results of the investment and operating costs calculation, combined with the final block layout, form the basis for a well-founded recommendation and schedule.

Recommendation and schedule with feasibility guarantee

At the end of the planning phase, there is an implementation recommendation with a concrete implementation schedule. Our company motto "thought. done" stands for realistic, practical implementation scenarios with a guarantee of feasibility.

On request, agiplan will accompany the implementation of the project as a general planner and / or through comprehensive project management services.

A proven, systematic procedure leads to an optimal result.
A proven, systematic procedure leads to an optimal result.
The added value of expert planning results from the coordination of material flow, system and processes with the planning data.
The added value of expert planning results from the coordination of material flow, system and processes with the planning data.
Calculation of areas, personnel costs, operating and investment costs based on the creation of variants.
Calculation of areas, personnel costs, operating and investment costs based on the creation of variants.
The end result is a recommendation with feasibility guarantee.
The end result is a recommendation with feasibility guarantee.




Dr. Udo Riedesel

Dr. Udo Riedesel

Head of Logistics