Which systems are typically controlled by an MFS?

These include stacker cranes in automated small-parts and pallet warehouses, conveyor systems, sorters, shuttle systems, and transfer stations to manual areas. The exact scope depends on the degree of automation of the respective facility.

Can an MFS be operated without a WMS?

In simple facilities, operation without a fully featured WMS is theoretically possible — for example, when orders are passed directly from an ERP system. In practice, however, the combination of MFS and WMS is the standard approach, as the division of responsibilities makes both systems more efficient.

How important are real-time requirements for an MFS?

Real-time processing is a fundamental technical requirement. Delays in control can lead to backlogs on conveyor systems, collisions, or facility shutdowns. This places particular demands on server infrastructure and network architecture.

Is the MFS vendor-specific or can it be used independently of the manufacturer?

This varies by vendor and is a frequent point of discussion in tender processes. Some MFS solutions are closely tied to specific system technology, while others offer open interfaces for heterogeneous system environments. You should explicitly require interface openness in your specification document.

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MFS

Also: Materialflusssteuerung, Materialfluss-Steuerungssystem, Material Flow Control, MFC, Leitrechner

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In brief

MFS (Material Flow Control) is a software layer that controls and monitors the physical transport of goods within an automated warehouse in real time. It connects higher-level warehouse management systems with the programmable logic controllers of conveyor technology and warehouse machinery.

Key facts

The MFS controls all transport movements within an automated warehouse facility in real time, making it the operational hub between IT and machinery.
It communicates bidirectionally: upward with WMS and ERP systems via IT interfaces, and downward with the PLC controllers of conveyor technology.
In the event of a fault, the MFS takes over error detection, triggers alternative routes, and alerts operations personnel via a visualization system.
The openness of interfaces is a key selection criterion, as proprietary protocols increase long-term vendor dependency.

What is a Material Flow Control System?

The Material Flow Control System (MFS) forms the central control layer in automated warehousing and distribution facilities. It receives transport orders from the Warehouse Management System (WMS) and translates these into concrete control commands for conveyor systems, stacker cranes, sorters, shuttle systems, and other warehouse machinery. In doing so, the MFS communicates upward with IT systems via standardized interfaces and downward with the programmable logic controllers (PLCs) of individual system components. Without a functioning MFS, automated facilities cannot operate.

How does an MFS work in practice?

As soon as a picking or putaway order is triggered, the MFS takes over route planning within the facility. It calculates optimal transport routes, assigns transport orders to individual conveyor elements, and coordinates traffic rules to prevent congestion or collisions. At the same time, the MFS continuously captures status messages from all connected devices — from light barriers and barcode readers to weighing modules. In the event of a fault, the system detects the error, initiates alternative routes, and notifies operators via a visualization system. Many MFS solutions also offer an integrated control panel through which maintenance teams can intervene manually.

The volume of data that an MFS processes in real time in a larger automated warehouse is substantial. Latency times in the millisecond range are not the exception but a technical prerequisite for smooth operations. For this reason, MFS applications frequently run on dedicated, hardened server systems with fault-tolerant infrastructure.

What matters when choosing a system?

When selecting a system, you should examine the following aspects particularly carefully:

Interfaces: How open and standardized are the APIs to the WMS, ERP, and PLCs? Proprietary protocols increase vendor dependency and make future expansions more difficult.
Scalability: Can the MFS integrate additional system modules or sites without requiring a complete redevelopment?
Fault management: How detailed and traceable is the error diagnostics? Does the system offer automatic rerouting or only manual intervention?
Visualization: A powerful control system display simplifies day-to-day operations for the operations team and significantly reduces response times.
Maintainability: Is the MFS documented to a level that allows internal IT teams to make configuration changes independently, or is there a permanent need for external service providers?

Whether the MFS is deployed as a standalone system or as an integrated module within a WMS vendor's offering is not consistent across the industry. Both approaches have advantages and disadvantages that depend heavily on the degree of automation and the existing IT landscape.

Frequently asked questions

The WMS manages inventory, orders, and storage locations at a business operations level. The MFS translates these orders into physical transport movements within the facility and communicates directly with the machine control layer. Both systems are closely interlinked but functionally clearly separated.

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.
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.
API
An API (Application Programming Interface) is a defined interface through which two software systems can exchange data in an automated and standardized way. In intralogistics, it connects systems such as WMS, ERP, or TMS with one another and with external services.
Abnahmeprozess (FAT/SAT)
The acceptance process (FAT/SAT) comprises two consecutive test phases used to verify that intralogistics systems comply with contractual requirements before commissioning.
AutoStore-Lagersystem
The AutoStore storage system is a fully automated cube storage system in which robots stack, retrieve, and transport plastic bins across a three-dimensional grid structure to stationary picking stations.
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.
Automatisierung
Automation refers to the use of technologies and systems to execute processes fully or partially without human intervention. In intralogistics, the spectrum ranges from simple conveyor systems to fully automated high-bay warehouses with autonomous vehicles.
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.

Matching categories

Automate warehousing Integrating Systems & Interfaces Connect ERP, WMS & TMS Managing exception processes Developing automation concepts

MFS