Efficiently bundling transports and thereby guaranteeing a high frequency supply with the best of equipment – this is one of the key themes of our most recent IPO.Log version.

Planning of tugger train systems

Various factors such as frequency planning and timetable generation often make planning tugger train systems a difficult part of intralogistics.

A design based on resource evaluation is required to determine the optimal tugger train concept.

IPO.Log evaluates these resources to determine specific propositions for both rough and detailed planning.

When are your tugger trains practical and profitable?

Based on a real production program, IPO.Log calculates backwards from the point of instillation to determine the earliest and latest possible delivery time. This ensures that the required materials are available on time and at their required location.

IPO.Log software can be utilized to determine tugger train profitability and which resources are required. Different scenarios can be evaluated and temporary peak loads can already be identified during the planning stage.


Depending on the planning stage (rough planning, detailed planning, series planning), key statements about the following performance indicators can be made with IPO.Log:

Tugger trains in 3D

Information provided by IPO.Log

Tugger train requirements

Number of tugs, number of trailers on a type-per-type basis


Precise information on the required number of employees (tugger train drivers and logistics staff)

Tours per day

View the tours in a chronological sequence

Complete route

Layout based evaluation of individual routes

Process times

Loading, driving, unloading in the form of a Gantt chart

Static and dynamic

In the rough planning phase the time of provision calculation is based on the logistical quantity structure. In the detailed planning phase the production program serves as the time basis from which the times of provision are calculated.


The evaluation shown below depicts dynamic tugger train planning. The various routes are color coded. The total number of tugger trains required at any given point in time is shown in black.

IPO.Log uses a 3D model and detailed evaluation to offer concrete possibilities for planning and optimizing tugger trains. Time based simulation has the advantage that tasks such as loading, driving and unloading are easily visible in a Gantt chart.

In the animation and simulation phase pictured below, the tugger train runs through the hall in the 3D model at the correct time and based on source-sink correlations.

Route planning of tugger trains


Bottlenecks can also be recognized using direct evaluation and solutions can be developed and simulated in IPO.Log.


Traffic volume in the hall at any given point in time can be dynamically displayed in the form of a heatmap. The more intense the coloring means that more vehicles are operating on the same route at that moment. The planned route can be precisely evaluated and adapted if necessary. This directly calculated feedback expedites the planning process and leads to a more reliable outcome.

Dynamic heatmap for tugger train planning
IPO.Log Planning Software

Added value and benefits


Layout-based creation of routes

Tugger train requirements

Calculation of tugger train requirements via defined material flow chains


Dynamic route calculation of transport orders based on time of provision

Order list

Order list with earliest and latest time of provision and source-sink correlations


Time based analysis of tugger train planning with load peaks

Theo Schwarzwälder
Your Contact person Theo Schwarzwälder
Phone: +49.7152.70010.54
> Contact form

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Future-proof planning with IPO.Log

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