The path to installing a tugger train system

Step by step to lean logistics

The path to installing a tugger train system

The potential of lean logistics is not yet being fully exploited. The strategy has many clear benefits and offers a significant competitive advantage.

‘Only that which changes can remain’ is the company’s approach to remaining flexible and ultimately competitive on the market. Lean logistics incorporates classic lean methods and uses these to optimise logistical processes, such as eliminating unnecessary process steps.

The advantages of lean logistics

Supply can be timed perfectly: just-in-time or just-in-sequence:

  • Just-in-time: the required goods are delivered to a precise location in the right quantity and at the right time for further processing.
  • Just-in-sequence: the goods are also delivered in the right sequence as required for production, which is often necessary as a result of growing product variation and individualisation.

Forklift-free production reduces the number of trucks required in the material flow, thereby saving investment and operating costs.

The processing time per carrier is reduced to a minimum.

The work processes become faster, more efficient and more secure.


We have summarised the advantages of tugger train systems in this white paper in order to present a comprehensive argument for introducing tugger trains as part of a lean logistics strategy.

How lean is your material supply process?

If the answer to the following questions regarding the current status of your warehouse and transport logistics is ‘YES’, you should carefully consider introducing lean principles:

1. Do you often have surplus production?

2. Do you have unnecessary stock?

3. Are there delays in your process chain?

4. Do you see potential to make your production processes more efficient?

5. Do your employees express dissatisfaction regarding ergonomics, work safety or other workplace processes?

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Lean introduction: step by step to the tugger train concept


1. The lean idea

You already know what you want: to make your production fit for the future. Once you have decided to introduce lean processes, external consultation can help you take the first steps. These steps primarily include defining the purpose of the process, including the necessary participants within the company and creating a shared understanding, as it is crucial for employees to accept the introduction of lean principles if the project is to be a success.


2. Analysing the current situation

A lean expert will examine your processes carefully and will look at the strategies currently in place: How is the value-added chain structured? How are the processes organised? How many forklift trucks are in your fleet? How is the material flow process designed? Which of the activities, transport routes and processes are unnecessary?


3. Hitting targets

Without a target there can be no strategy. It is therefore important to bring the company targets and the aims of lean management into line: What are the short, medium and long-term company targets? How can these targets be met using lean methods?