Build a smarter material flow strategy with simulation
The Konecranes Material Flow Engineering Study is designed to provide a comprehensive analysis, design and optimization strategy for the movement of materials within a production system.
Our engineers use highly accurate and dynamic simulation models to assess and verify capacity and performance. From this analysis, we provide recommendations on system design and capacity, the number of overhead cranes and performance requirements, as well as insight in the operational rules of such a system.
The engineering study can be applied in a wide range of applications as well as intralogistics systems such as cranes, forklifts, high bay storage systems, conveyors, trucks and trains.
Benefits of an engineering study
- Provides a validated concept, verifying the feasibility and effectiveness of a proposed solution.
- Provides optimized layout recommendations for facility design to achieve the best material flow.
- Assists in defining needs and making strategic choices, especially in early project phases when requirements may be unclear.
- Offers a foundational design framework for projects.
Simulation-driven insights for smarter material flow decisions
We use simulation models to provide a clear, data-backed picture of how materials move through a facility and where improvements can be made to boost safety, efficiency and throughput. Depending on project needs, we offer different levels of simulation. The right level is determined by factors like whether a project is greenfield or brownfield, how much process detail is already defined, and how much confidence is needed before moving forward.
Process visualization
Simulation models including system components show how materials would move through a facility and how the system would behave, built on reasonable, common-sense assumptions about movement and timing. This visualization helps bring the concept to life and makes it easier to explain, without the extra time and cost required to develop detailed process data.
CORE DELIVERABLE
Animated visualization of the process.
System simulation
This simulation incorporates defined process times, equipment behavior, and process inputs like how often materials arrive at the system. With this detail built in, different scenarios can be run to see how the system performs, answering questions like how much it can handle, where bottlenecks form, and how efficiently it runs.
CORE DELIVERABLE
Concrete statistics and KPIs relevant to the business—like throughput, utilization, and wait times.
Benchmarked simulation
Simulation results are validated against an existing system to verify accuracy. If a direct comparison isn’t available, detailed modeling of selected process steps will be used for validation with customer approval. This validation provides greater confidence in the results before using them to make major decisions.
CORE DELIVERABLE
Customer-approved KPIs with a high degree of confidence in result accuracy.
Virtual commissioning or emulation
The simulation model is connected with your real or virtual control systems (such as a PLC or warehouse management system) to test the actual control logic, interfaces, and system behavior—essentially a dress rehearsal for your control software. It’s useful when the goal is to catch issues with system logic and integration before anything goes live.
CORE DELIVERABLE
Verified control logic and a lower risk of surprises during commissioning.
Our approach
Your partner in end-to-end material flow solutions
For decades, we’ve supported process industries with reliable, integrated lifting and material handling solutions—designed to improve efficiency and reduce risk. Our in-house engineers support planning, delivery, commissioning and service, with deep knowledge of process demands and reliability needs. Whether for new builds or facility upgrades, we provide expertise spanning cranes, high-bay storage, forklifts and other material handling technologies to help improve efficiency, reliability and safety.
Get in touch with our experts to see how a Material Flow Engineering Study can benefit your operations.