Ludwigshafen, October 19, 2026 – What is the right material flow architecture for automated warehouses? This question was the focus of the webinar “SAP MFS or an External Material Flow Controller? The Right Architecture for Automated Warehouses,” hosted by LogiPlus Consulting on September 29, 2026. Thilo Matheis, CEO of LogiPlus, explained the differences between SAP MFS—the material flow control system integrated into SAP EWM—external material flow computers (MFRs), and combined approaches. Key takeaway: In most automation scenarios with SAP EWM, SAP MFS offers significant advantages in terms of integration, flexibility, and operation. However, the existing system landscape and logistical requirements remain decisive factors.
Material flow control integrates warehouse management with automation technology. Among other things, it handles routing within the system, communication with programmable logic controllers (PLCs), and the management of malfunctions and exceptions.
While external material flow computers create an additional system layer between SAP EWM and plant control, SAP MFS is directly integrated into SAP EWM. This means that warehouse and material flow processes access the same database. There is no need for additional interfaces, duplicate master data, or time-consuming synchronization processes.
“In principle, we have distributed the logic either within a single system or across two levels. That is essentially the major difference in terms of architecture,” Matheis explained.
A key advantage is operational flexibility: priorities, resources, and warehouse orders can be managed directly in SAP EWM and adjusted at short notice as needed. In addition, the system offers standardized monitoring, reduced dependence on specific manufacturers, and lower maintenance and operational costs.
Using specific automation scenarios, Matheis demonstrated that SAP MFS is a powerful solution, particularly for conveyor systems, high-bay warehouses, automated small-parts warehouses, and shuttle systems with open PLC interfaces.
External control systems, on the other hand, may still be useful for existing facilities or closed manufacturer systems. These include, for example, certain robotic solutions or AutoStore systems that use manufacturer-specific controllers. A phased modernization of existing facilities may also require the parallel use of different control systems.
The architectural decision should therefore be made early on, taking into account interfaces, responsibilities, and the long-term operating model. In addition to technical requirements, maintainability, the ability to release updates, and operating costs over the entire plant lifecycle play a particularly important role.
Two live surveys conducted during the webinar highlighted just how relevant this topic is for companies. About 22 percent of respondents are already actively evaluating SAP MFS as an alternative to an external material flow control system. Just over 17 percent are planning a new automation project, and another 17 percent are planning to modernize existing systems. An additional 8 percent are looking to replace an existing material flow control system.
In terms of the time horizon, about 44 percent of respondents plan to launch a specific project within the next two years. At the same time, many companies are still in an early phase of gathering information and exploring options. The results underscore that choosing the right material flow architecture is important both for current projects and for long-term automation strategies.
The takeaway from the webinar: SAP MFS is the obvious and economically sound solution for many automation projects managed using SAP EWM. However, there is no single architecture that is equally suitable for every facility. The key factors are the logistics processes, the automation technology used, and the requirements for future operations.
In doing so, LogiPlus adheres to its “Logistics First” consulting approach: It is not technology that dictates logistics, but rather logistics requirements that determine the appropriate system architecture.
Companies that wish to evaluate their existing or planned material flow architecture can discuss their requirements in an online session with LogiPlus’s SAP EWM and intralogistics experts and explore suitable solutions.
Then take the opportunity and request your online appointment with our SAP EWM experts now. We will be happy to support you so that you can assess how you can further optimise your intralogistics processes.
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