Efficient Intralogistics Planning Based on an Innovative Intralogistics Tool using the Example of a Flexible Battery Cell Factory

Abstract

In the course of increasingly volatile markets, globalization as well as shorter product life cycles, factories and thus also the logistics system as a central component of a factory have to be designed in a more flexible way. Battery cell production faces a special challenge in this aspect. Due to the trend towards a sustainable and environmentally friendly energy supply and mobility, the demand is expected to increase significantly. New battery cell factories have to manage rising product volumes and simultaneously react versatile regarding new research findings. Thus, the market for battery cells, the product itself, and the corresponding manufacturing processes are constantly changing. New materials, manufacturing methods, variations of cell formats as well as the possibility of scalability and the associated changes in the requirements for the factory must be taken into account as early as possible in the planning stage. The logistics system as one of the core elements of a factory is always affected by changes in the product, manufacturing processes or input materials. If, for instance, other materials are used, the storage and transport of these goods with different dimensions, weight or even environmental requirements must still be guaranteed. In order to consider the required flexibility already in the planning process, simulation can provide a decisive benefit. It enables the planner to analyse the production and iteratively adapt logistics planning. Since there are many possibilities and combinations, especially in the design of warehouse and transport systems, a reduction of these should take place at an early stage. However, the preselection of suitable logistics systems that provide the necessary flexibility is currently often based on empirical knowledge and extensive market research. Therefore, this paper presents an efficient, holistic approach to logistics planning and an intralogistics tool in detail, which is based on established data. As a result, an optimal logistics system can be defined through an iterative optimization of the flexibility corridor, taking into account the factory goals.