Malaga V4

Materials flow Analysis - Layout Analysis - Graphic Association


Malaga V4 is a comprehensive software suite for

  • Logistics Planning
  • Logistics Simulation
  • and Factory Planning

The software was developed together with our partners from the automotive industry and is a central component of the digital factory. The programs offer a holistic approach with a common database and consistently linked tools, methods and models.

The economic efficiency is shown in the slide opposite (logistics kit for the digital factory)
Economical means optimizing manufacturing processes and using resources in the best possible way from an economic and – increasingly important – ecological perspective.

Malaga V4 offers you the following advantages:

  • Improving the quality of the planning process through automated processes and validation of your planning data. Malaga shows potential for rationalization and thus serves as a basis for decisions.
  • Thanks to standardized interfaces, Malaga fits seamlessly into your IT landscape.
  • A variety of evaluation and reporting functions enable a professional presentation of your results.
  • The simulation deepens the insight into your production processes, reveals further optimization options and makes it possible to check the static planning results again.

 Key Features:

  • Graphic planning directly in the CAD system (Microstation).
  • Multi-user capability and central data storage: All users work on the same database: redundant and potentially contradictory data are therefore excluded.
  • Complete consistency and a common language from data transfer to simulation.
  • Extensive automation of the planning process opens up rationalization potentials, making decisions more efficiently.
  • Simulation - the dynamic model
    With the layout, the model of the factory is already at hand; all necessary data are available, just you have to start the simulation.

Malaga V4 - Features

Product   Process   Resource
The Product area covers the article codes,
including the master data and bill of materials.
The bill of materials contains the informations about resources and production processes,
and serves als basis for the creation of the assembly priority plan.

With the help of e.g.the Excel interface the product data product data can be taken over from other systems.

  The process area contains reusable standard processes and the assembly priority graph. All logistical relationships can be modeled graphically in the process editor.
  • Full and empty materials flow.
  • Assembly processes.
  • Container exchange.
  • Additional production rate (for scrap, spare parts, CKD etc.)
  • Complex handling processes.
  • Folded empty cartons.
From this, among other things, the following results are generated:
  • Total and partial costs.
  • Part/Containers throughput.
  • Number of bound containers.
  • Number of necessary vehicles.
  • Staff requirements.
  • Lead times.
  The Resource area contains container,
groups of personnel, various transportsystems as well as cost rates and shift models.

Also innovative logistics concept such as trugger trains and trolleys can be illustrated with Malaga.

The following results, among others, are calculated for the respective objects:

  • Personnel requirements.
  • Cost.
  • Number of vehicles required.
  • Time shares for transport and handling.
  • Distance traveled.
  • For tugger trains:
    • Optimal cycle time.
    • Number of trailers required.
  • Total demand.
  • Calculatory interest rate.



General features

All Malaga data are linked to drawing objects in the layout draft.
In this way you get a graphic representation of all material flow directly in the layout.

This is done entirely in 3D, so that even multi-storey systems can be depicted.

The following analyzes are possible, among others:
  • Area requirements.
  • Total cost.
  • Necessary workplace.
  • Shortest paths.
  • Load of paths.
  • Automatic calculation of a cost-optimal allocation of available area to process Stations.

Automated design support:

  • Built-in scheduling features make otherwise time-consuming tasks easier.
  • Incomplete or incorrect data will be shown.
  • Optimization functions configure their quantity structures automatically.


  • Comprehensive role-based rights concept.
  • Changes are immediately reflected in the database. It is not necessary to save the data manually
  • All changes can be undone (Undo & Redo).


  • XML-based import and export of all planning data.
  • Import of product data via Excel.
  • Table-based configurable reports can be exported to Excel.


  • All masks are configurable and can therefore be adapted to your individual needs.
  • The user interface speaks several languages depending on the user (currently German, English and Chinese).

Library concept:

  • Objects that can be used across projects, such as: containers and transport systems can be stored in the library and are therefore available to all users.

Simulation "Massimo"

With the simulation interface “Massimo” all planning data from Malaga including the factory layout can be utilized to build a running Plant Simulation model.
No expert simulation knowledge is required – the simulation runs completely in the background, so that no user interaction is required.
The resulting model however can be adapted and elaborated further by simulation experts.

With an existing Malaga project only a few steps remain to get to a runnnig simulation model.
When all data is complete the simulation can be started by a push of a button.




  • The time to create a simulation model is considerably reduced while the quality of the resulting simulation model is improved:
    • All necessary information and data has already been collected in Malaga.
    • All geometric positions will be retrieved from the layout drawing with millimetre precision.
    • The input data is transparent and its consistency can easily be checked.

Dynamics Modelling:

  • You can choose if you want to sketch the information flow in the process editor or if you want to use the automatically generated Kanban-control.
  • By creating vehicle pools you can exactly define the operational area of each vehicle.
  • The production plan can be created automatically or imported from MS Excel.
  • For all necessary input properties Malaga calculates meaningful default values.




  • Experiments with different seed values for statistical safety.
  • User defined duration of the settling phase.
  • Results of different experiments can be compared easily.
  • Faulty or incomplete objects are detected automatically.
  • You can assign planned failures to all vehicles and stations to check the robustness of the logistics system.
  • The abiblity to compare the results of the simulation with the calculated results makes it easy to check your model for plausibility.

In addition to Malaga the following software is required to run the simulation:


References Malaga

Malaga is successfully applied at:


  • Research and Innovation Center (FIZ) Munich
  • Munich plant
  • Regensburg plant
  • Leipzig plant
  • Dingolfing plant
  • Oxford plant
  • Spartanburg plant, USA
  • Rosslyn plant, South Africa




  • Wolfsburg plant
  • Salzgitter plant
  • Braunschweig plant
  • Emden plant
  • Kassel plant
  • Kaluga plant, Russia
  • Plants in China, Brazil



  • Plants in Sweden, Brazil






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