Mr. Schulz, what exactly is a material flow computer and how does it differ from other systems?
A material flow computer - MFR for short - is software for the complex control of data and information flows in automated systems and warehouses. The MFR takes over the communication between the individual components, so to speak. It is clearly differentiated from systems such as ERP or MES: The MFR controls the system on the basis of transport orders for individual loading equipment.

Why are material flow computers so important in today's modern production?
In times of highly automated processes, it is essential to connect individual system components with each other. An MFR offers precisely this possibility: many individual components, even from different manufacturers, become one system.

What does the interaction with other systems such as ERP and production look like, for example?
The MFR provides an interface via which an ERP system sends the transport orders to the MFR and via which the MFR reports the status messages back to the ERP. The MFR also has downward interfaces to all system components to be controlled in order to exchange information with them.
The MFR divides a transport ordered by the ERP system into different partial transports depending on the source or destination, plant utilization and possible faults. It always sends a partial transport to the part of the system in which the loading equipment is currently located. In this way, the loading equipment is guided through the system piece by piece until it has reached the final destination requested by the ERP. The MFR can also perform other functions for system control: Management of capacity utilization - i.e. queue management, control according to specific strategies, path-optimized control of transfer carts and storage and retrieval machines and much more.
An MFR should provide comprehensive visualization for all of these control functions so that the operator can see what is running when and why, or quickly identify faults. However, 'visualization' does not mean system visualization, but rather a representation of the MFR control functions.

In the warehouse, for example, there are palletizers or conveyor technology areas that are each controlled independently. However, when a transport reaches the end of its responsibility, the MFR ensures that the next component takes over and the transport continues.

© Sysmat

Different systems from different manufacturers are often used in companies' supply chains. Does this lead to problems and how can they be solved?
■ That's right. Companies usually have several plants and systems from several manufacturers with different interfaces and functions in use. If plants are to be integrated into existing ERP systems, the ERP system would have to control each part of the plant individually. This process is already very time-consuming for one plant. As the MFR is connected between the ERP system and the plant, the MFR takes over these tasks. It controls each system individually for the ERP. For the user, it looks as if all systems are the same. It is only through the flexible interfaces offered by the MFR that the systems can be linked together.

How exactly is the connection between the different systems implemented?
■ The MFR establishes connections to the individual components and systems in the manner expected by the respective system manufacturer. The interface is programmed accordingly. We have dealt particularly intensively with the interface issue. Our own material flow computer Matcontrol Graphics now has over 20 interfaces for various manufacturers, including Daifuku, Dambach and Köttgen. There is also an interface for SAP, which integrates all systems into the existing ERP system.

Can you give us an example of how a system is connected via an interface?
■ Basically, commands for controlling a machine or system - so-called telegrams - are transmitted via an interface. These telegrams contain a whole range of information. The different systems normally need similar data - for example, source and destination coordinates. This is because the system then knows where a pallet or container should be picked up and where it should be returned. Nevertheless, these telegrams look completely different for each manufacturer because they speak different 'languages'.

The telegrams are usually divided into several fields. One important field, for example, is the 'type' of telegram. For example, codes such as 201 for 'order for putaway', 205 for 'transport order' or 210 for 'cancel order' or, in the other direction, 105 for 'transport completion message' or 103 for 'shelf storage completion message'. Thanks to the 'Type' field, each partner can see what the telegram is intended for and how it is to be evaluated. Other fields, such as source and destination coordinates, loading equipment ID, loading equipment type or loading equipment height, are formatted differently depending on the system and manufacturer and must be standardized.
There are also different procedures for transmitting the telegrams. And here too, the different 'languages' of the system and the manufacturer must be taken into account. Each partner of such an interface expects a precisely described syntax for a particular telegram. The telegram is often rejected if the smallest error occurs.

Programming an interface is a very complex process - as is commissioning it. That's why we have made our interfaces configurable in order to emulate the manufacturer's interface - eliminating the need for changes to the PLC and long test phases with the system.

What tips do you have for introducing an MFR?
■ In addition to visualizing the system, the software should provide options for simulation. Such a function offers the opportunity to test new settings in advance without stopping the entire production process. Ultimately, the company avoids errors only being detected during operation and production being delayed. I also recommend in-house commissioning. The software is installed during ongoing operations. Training for employees can be linked to the test operation of the new software. Overall, this results in a time saving of 70%.