Materialflusssteuerung
Also: MFS, MFC, Materialfluss-Steuerung, Materialflussrechner, Material Flow Control, Material Flow System
AI-generated
Material flow control refers to the software-supported coordination of all transport movements within an automated or semi-automated warehouse and conveyor system.
Key facts
- Material flow control coordinates transport orders, routing, and buffering across systems between PLC and WMS.
- It is a standalone software layer and not part of the machine control (PLC) of individual facility components.
- Clear interface and responsibility boundaries between MFS, WMS, and facility supplier are critical for smooth operations.
- Metrics such as throughput per hour, fault times (MTTR), and buffer fill levels directly measure the efficiency of the MFS.
- The scalability of the MFS when expanding facilities is a key selection criterion and is addressed differently depending on the vendor.
What is material flow control?
Material flow control – commonly abbreviated as MFS or MFC – is a software layer that coordinates the physical flow of goods in automated warehouse and distribution facilities. Architecturally, it sits between the programmable logic controller (PLC) of individual machines and the higher-level warehouse management system (WMS). While the PLC addresses individual actuators and sensors, the material flow control handles the cross-system logic: which unit goes where, via which route, with what priority, and in what buffer state?
How does material flow control work in practice?
In a typical facility, the material flow control receives transport orders from the WMS or ERP system and breaks them down into specific movement commands for conveyors, sorters, stacker cranes, shuttles, or autonomous vehicles. In doing so, it handles the following core tasks:
- Routing: Calculating the optimal path for each load unit through the conveyor network, taking into account route utilization and restricted zones.
- Prioritization: Managing right-of-way rules, for example for urgent orders, replenishment runs, or returns.
- Buffer control: Active management of intermediate buffers to balance throughput peaks and prevent blockages.
- Communication: Bidirectional real-time data exchange with PLC systems via standardized protocols.
- Monitoring and fault management: Seamless tracking of every load unit as well as automated initiation of alternative routes in the event of system faults.
The result is end-to-end tracking of every load unit from goods receipt to the dispatch area – without manual intervention under normal conditions.
What matters when making a selection?
Several factors are critical when selecting and implementing a material flow control system. First, the interface to the WMS must be clearly defined: who issues transport orders, and who reports status changes back? This boundary of responsibility varies by vendor and should be contractually specified. Second, scalability plays a role: can the MFS integrate new subsystems when the facility is expanded without requiring a complete redevelopment? Third, real-time capability is critical – especially in high-throughput facilities handling several hundred load units per hour, where latency can directly lead to congestion. Finally, fault management should be evaluated: how quickly does the system detect an error, what alternative strategies are available, and how transparently are the cause and resolution time documented? The answers to these questions vary considerably depending on the vendor and facility concept.
Related terms
- AGV
AGV (Automated Guided Vehicle) refers to driverless transport vehicles that automatically move goods in warehouses and production environments. They follow predefined or sensor-controlled routes without a human driver.
- AKL
An Automated Small Parts Warehouse (AKL) is a fully mechanized storage system for bins, trays, or cartons that automates the goods-to-person process using aisle-captive storage and retrieval machines or shuttles.
- AMR
AMR (Autonomous Mobile Robot) is a driverless, self-navigating transport robot that moves goods within a warehouse without any fixed installed infrastructure. It orientates itself independently using sensors and digital maps, and dynamically avoids obstacles.
- Auslagerung
Retrieval refers to the physical process by which goods or load units are removed from a storage area and transferred to a downstream process – such as picking or shipping.
- AutoStore
AutoStore is a cube-based automated storage system in which driverless robots traverse an aluminum grid to stack plastic bins and retrieve them on demand for delivery to picking ports. The system is considered one of the most space-efficient automated small-parts warehouses available for standardized bin-compatible goods.
- Automatiklager
An automated warehouse is a fully or partially automated storage system in which the receipt, retrieval, transport and management of storage units are carried out without manual intervention, using conveyor technology, storage and retrieval machines, and a higher-level control software.
- Automatisches Kleinteilelager (AKL)
The Automated Small Parts Warehouse (AKL) is a fully automated storage system for totes, trays and small parts, in which storage and retrieval operations are performed without manual intervention by stacker cranes or shuttle systems.
- Bottleneck Analyse
Bottleneck analysis identifies the process step with the lowest capacity in a logistics system, making the limiting factor for overall throughput visible.
- Disposition
Disposition refers to the operational planning and control of resources, quantities, and orders in logistics – for example in transport or materials disposition. It encompasses capacity assignment, scheduling, prioritization, and response to disruptions.
- SPS
A Programmable Logic Controller (PLC) is an industrial computer that controls and monitors machines and systems in intralogistics through freely programmable logic. It forms the lowest automation level and communicates with sensors, actuators, and higher-level control systems.
- WMS
A Warehouse Management System (WMS) is a software solution for the operational control and management of all warehouse processes – from putaway and picking to goods issue. It coordinates storage locations, inventory, resources, and staff deployment in real time.