Why it is worth using tugger trains

The advantages of tugger train systems

Why it is worth using tugger trains

Since lean production was first introduced in Japan in the 1960s, tugger train systems have stood for lean processes, timed logistics and traffic-calmed intralogistics. In production, these towing trucks with transport routes ensure demand-based supply and disposal of materials in accordance with the milk-run principle.

As they are similar to public transport train systems, they are also called tugger trains or tractors. Companies across a range of industries, from automotive to the supply industry, are increasingly relying on tugger trains for internal transport.

Advantages of the tugger train at a glance

The transition from a conventionally operated production logistics process to modern internal material supply using a tugger train system comes with many advantages:

  • Traffic calming
  • Increased safety in warehouse traffic
  • Increase supply and process reliability
  • Increase production in the same production space
  • Production becomes more individual and product variety increases
  • Financial advantages
  • Ergonomic work

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Traffic calming

It’s logical. A tugger train means much less traffic than several forklift trucks. A tugger train produces less noise, uses less energy, requires fewer employees and leads to reduced operating and service costs. The cyclical work process ensures that internal transport costs are kept at a steady level.

Sicherheit Lagerverkehr

Increased safety in warehouse traffic

Avoiding occupational accidents is a key part of smooth intralogistics. It is clear that one tugger train is safer than several forklift trucks crossing paths. This increases safety for the warehouse itself (e.g. at shelves), for the transported goods and above all for the staff. Tugger trains ensure better regulated and coordinated traffic within the company.

Erhöhung Versorgung

Increase supply and process reliability

Reliable supply of materials in order of sequence needed for production is ensured through production timetables. A pre-set cycle means that materials are delivered to the supply locations at specific times. This in turn determines the number of journeys and the journey times of the tugger trains.

Process reliability means establishing a process that is as simple as possible and easy to reproduce, which has good transparency when it comes to errors, and runs smoothly.


Increase production in the same production space

A typical reason for implementing a tugger train system is to increase production without enlarging the production space. Tugger trains are often used for supplying assembly areas in which a large number of different, small materials must be replenished quickly and regularly in small production spaces.