Analysis and optimization of intralogistics processes

It’s Monday morning in the warehouse. Operators are looking for pallets, goods have gone missing again, and production is calling because a component is missing. Unfortunately, this is a daily reality in some companies. More importantly, it’s a clear sign that it’s time to take a closer look at your intralogistics.

Analyzing and optimizing processes doesn't mean a revolution, but rather conscious changes that reduce chaos and errors. In this article, we explain what intralogistics process analysis is and how to improve operations to reduce financial losses and everyday problems.

Why is intralogistics so important?

Intralogistics encompasses all processes related to the transport, storage, and flow of raw materials, semi-finished products, and finished goods within the company. In practice, this means several stages - from receiving materials from the supplier, storing them, transporting them to the production line, all the way to preparing goods for shipment.

While external logistics focuses on deliveries to customers and distribution, intralogistics covers everything that happens under the company roof. That’s why it should - and must - operate as efficiently as possible. It directly impacts production continuity, costs, and the overall organization.

What does intralogistics process analysis mean?

What are the common problems companies face? Many deal with the same challenges: lack of space in the warehouse, disorganized workflows, or low operational efficiency. Add to that frequent picking errors, which increase costs and strain relationships with clients. However, it’s difficult to identify the root cause without a thorough process analysis.

Intralogistics process analysis involves:

identifying all activities related to the flow of materials and information
mapping the current state and identifying areas that require improvement
collecting both quantitative and qualitative data (transport time, error rates, space utilization, etc.)

Once you know these fundamental metrics, you can take real steps to reduce errors, losses, and operational issues.

After the analysis – it’s time for process optimization

Once weak points in intralogistics are identified, it’s time to implement improvements. Optimization is key - not as a one-time fix, but as an ongoing process. It typically includes the following steps:

1. Defining goals and priorities – it’s essential to set clear goals and KPIs (e.g., order fulfillment time, warehouse space utilization).

2. Developing an optimization plan – outlining actions, selecting appropriate technologies and methods (automation, Lean Logistics, system integration).

3. Implementing changes – applying new technologies, training employees, and adjusting processes.

4. Monitoring and evaluating results – continuous oversight is crucial to further refine operations.

How does an intralogistics optimization plan work in practice?

Each company’s analysis and optimization process looks a bit different. It’s a bit like a doctor’s visit - two patients might have similar symptoms, but different causes and treatments.

Not every company needs a full-scale intralogistics overhaul. Sometimes, basic improvements are enough. The actions often focus on improving:

internal logistics
digitalization of the company
industry 4.0 solutions
warehouse layout optimization
IT system configuration

A sample action plan for intralogistics optimization might look like this:

Project preparation – analyzing and selecting areas requiring immediate improvement, based on an initial audit. Creating a timeline for urgent actions, determining impact on the organization and required resources, and finalizing the optimization plan.
Change implementation – systematically executing tasks, generating reports, holding adjustment meetings to fine-tune activities.
Project closure – summarizing results, comparing them with original goals, making recommendations, and formally closing the project.

Also read: How to improve your goods storage process? Discover the stages of warehouse operations!

What can be improved in intralogistics optimization?

What steps can be taken to improve intralogistics performance?

Warehouse equipment

Many companies underperform due to poorly designed warehouses. Solutions such as high-bay racking, stacker cranes, and warehouse conveyors can help solve this issue (we’ll describe them later in the article).

Automation

It’s worth considering warehouse analytics, such as Warehouse Management Systems (WMS) or Enterprise Resource Planning (ERP) systems. These significantly reduce human error. WMS supports the management of goods flow, while ERP integrates the warehouse with other departments such as production, sales, and finance. Solutions aligned with Industry 4.0 - like RFID identification systems and AGV mobile robots - are also playing an increasingly important role.

IT system integration

Effective intralogistics relies on data consistency. Integrating systems like WMS, ERP, and automatic identification brings better results, such as faster response times to changes in orders or production.

What equipment supports intralogistics process optimization?

Companies investing in modernizing intralogistics can choose from a wide range of technologies. Key equipment includes:

Internal transport systems – roller conveyors, belt conveyors, and chain conveyors move goods either continuously or step-by-step. They automate transport between workstations, reduce manual labor, and shorten load transfer times.
Stacker cranes and storage systems – these automate the storage and retrieval of goods. A stacker crane moves both horizontally and vertically along the racking aisle, retrieving or storing loads at various levels. This reduces the need for manual work, improves safety, and cuts costs.
Warehouse lifts – these allow goods to be transported vertically - up to 20 meters high. This enables efficient use of facility height, eliminating the need to build new halls.

What are the business benefits? Greater efficiency, reduced costs, and faster order fulfillment. The company runs smoother, customers are happier, and the risk of returns or complaints drops significantly.

That’s why investing in intralogistics optimization equipment is a smart choice if you want to grow your business and increase profits. Choose from our stacker systems, lifts, and conveyors - contact us, and we’ll advise which solutions will yield the highest return.

FAQ – intralogistics process analysis and optimization

1. What is intralogistics?

Intralogistics covers all processes related to the flow of materials, raw goods, and finished products within a company - from material reception and storage, through transport to the production line, to goods preparation for shipment.

2. Why is intralogistics process analysis important?

Many companies face challenges like limited storage space, disorganized work, or order picking errors. Process analysis helps identify the root causes and plan effective improvements.

3. What does intralogistics process analysis involve?

It includes:

Identifying all activities in the material and information flow
Mapping the current process state and spotting weak points
Collecting quantitative and qualitative data (e.g., transport time, number of errors, space utilization)

4. What does intralogistics process optimization look like?

Optimization includes:

Setting goals and KPIs (e.g., order fulfillment time, space usage)
Developing an action plan and choosing methods (automation, Lean Logistics, system integration)
Implementing changes – new technologies, staff training, process adjustments
Monitoring and evaluating results for further improvement

5. What is a Quick Win variant?

These are rapid actions that deliver immediate results:

Project preparation: need analysis, area selection for quick improvement, timeline and resource planning
Change implementation: task execution, weekly reports, adjustment meetings
Project closure: summarizing results, creating stabilization recommendations, project wrap-up

6. What can be improved in intralogistics?

Automation: WMS, ERP, AGVs, RFID
IT system integration: syncing WMS and ERP for full process control
Lean Logistics: reducing waste, standardizing processes, optimizing warehouse layout
Warehouse equipment: high-bay racking, mezzanines, stacker cranes

7. What equipment supports warehouse optimization?

Internal transport systems: roller, belt, and chain conveyors
Stacker cranes and storage systems, including dual stackers for a single aisle
Automated ID and sorting systems (weighing, labeling, dimensioning)
Order picking aids (Pick-to-Light)
Integration with IT systems (WMS + ERP)

8. What benefits does intralogistics optimization bring?

Analyzing logistics and intralogistics processes helps achieve optimal process flow and smooth production operations. Implementing digital tools and new technologies like AMRs, robotic stations, or internal transport systems enables warehouse operations monitoring, bottleneck identification, and smarter decision-making.

With data analysis and route simulation, companies can optimize distribution and warehouse flows and better utilize staff potential. Investing in advanced data analysis tools pays off - with higher efficiency, lower costs, and increased customer satisfaction.