Tugger trains for lean production

What are tugger trains?

Tugger trains are an in-house transport solution designed to optimise the movement of materials within a facility. This type of transport plays a key role in supporting just-in-time and just-in-sequence production.

The tugger trains move configurations of trolleys through the factory, which can be loaded individually according to in-house requirements.

Materials are thus transported efficiently to or from machining centres or assembly stations, replacing the use of forklift trucks.

Benefit from the advantages of this tried-and-tested system

• Minimisation of empty runs
• Faster and safer than transport by forklift
• Different materials can be transported together
• Savings on forklift and labour costs
• Thanks to the virtual coupling/drawbar system
  , the train maintains excellent directional stability

Within the framework of lean production, the aim is to synchronise supply processes with production.

On the path to lean production:

To this end, tugger trains are increasingly being used in practice for internal transport, as they enable the high-frequency delivery of small quantities to points of demand whilst also promising efficiency gains in the area of intralogistics material supply.

Standardisation:

• JUST-IN-TIME
  (the right quantity at the right time in the right place)
• Elimination of the 7 MUDAs

Def.: ‘MUDA’: the Japanese word for pointless waste

MILK-RUN trains

The milk-run system is used to transport materials or goods in a regular cycle. As a rule, the quantity, time and route are fixed. This system increases the frequency of material deliveries and leads to a more even utilisation of capacity within the specified time window.

In production, existing safety stocks and unrecorded residual stocks are eliminated. General stock levels are also significantly reduced.

Furthermore, switching to the milk-run system can yield substantial savings in labour and machinery costs. The savings realised can then be channelled into other efficient tasks within the value chain.

Definition: ‘Milk-run’ originally referred to the system used by the milkman, who would exchange empty bottles for full ones at households. This system has been adapted for use in procurement logistics and material supply within production.