In brief
A material flow analysis examines quantities, routes, frequencies, times and inventory between sources and destinations. Sankey diagrams reveal quantitative relationships, value stream analysis connects material and information flow, and simulation tests dynamic interactions under changing loads.
Sankey diagram
Sankey diagrams represent material quantities through weighted connections. They are suitable for revealing dominant relationships, crossing traffic and consolidation potential. Their limits become apparent when time-dependent behaviour, queues or control rules are decisive.
Value stream analysis
Value stream analysis connects process sequence, inventory, times and information triggers. It supports a shared discussion of an end-to-end process and exposes waste between processing steps. Complex networks with many product families first require meaningful segmentation.
Material flow simulation
Discrete-event simulation represents dynamic interactions between resources, disruptions, buffers, priorities and shift calendars. It is worthwhile when static averages cannot provide a reliable view of peaks, queues or mutual blocking. The model should be as simple as possible and as detailed as necessary.
Method selection matrix
| Planning question | Suitable method | Typical result |
|---|---|---|
| Which relationships dominate? | Sankey | Quantity view and transport relationships |
| Where do waiting time and inventory arise? | Value stream | End-to-end process view |
| How does the system behave at peak? | Simulation | Dynamic KPIs and scenarios |
| Which routes cross in the layout? | Spaghetti and layout analysis | Routes, distances and conflict points |
From analysis to action
The method is only the first step. Every observation needs a cause, a target KPI and an implementable measure. Three levels help with prioritisation: change the process, change the layout or introduce technology. Impact, effort and risk are evaluated separately.
Learn more about our material flow analysis, the glossary entry on material flow planning and the practical article on layout optimisation.