Coordinate Internal Material Flows Digitally with the Zebra TC201 and COSYS

COSYS connects warehouse management and internal transport within a single supply chain software environment. The Zebra TC201 serves as the mobile device used directly within these processes. Employees record material movements where they actually take place, while the resulting data can also feed into Business Intelligence, forecasting and Process Mining. This means companies can not only execute material flows digitally, but increasingly manage and optimise them based on real operational data.

Supply Chain Software Connects Warehouse and Internal Transport

A typical workflow demonstrates the benefit of an integrated solution. Goods arrive at receiving and are recorded using the mobile data capture device. COSYS Supply Chain Software records the item, quantity and storage location. During put-away, transfers and picking, employees are guided through the relevant mobile workflows and each important material movement is documented.

If the material then needs to be moved to another operational area, the warehouse movement can trigger an internal transport order. COSYS IBT handles the subsequent coordination. Transport orders can be scheduled, prioritised and assigned to employees, vehicles or load carriers. Collection, loading and delivery are confirmed digitally, giving dispatchers visibility of the current status without having to contact employees individually.

Warehouse and transport operations therefore no longer function as separate processes. The material flow remains traceable from inventory through to its internal destination.

Zebra TC201 Brings Digital Processes to the Point of Work

Operational software needs hardware that can handle different tasks throughout the working day. This is where the Zebra TC201 comes in. The full-touch mobile computer is designed for applications including receiving, put-away, picking, shipping, inventory control and asset management. This makes it particularly suitable for activities at the interface between warehouse operations and internal material flows.

Barcodes can be captured directly during warehouse and transport movements. The SR500 scan engine is available for standard scanning distances, while the optional AC670 Advanced Range Scan Engine can capture barcodes from distances of up to 30 metres according to the manufacturer. This can be particularly useful at larger logistics and industrial sites where labels may not always be within immediate reach.

Its rugged design also supports use between warehouse, production and outdoor operational areas. The TC201 is rated to IP65 and IP68 for protection against dust and water and is specified for operating temperatures from -20°C to +50°C. Wi-Fi 7 and, depending on the model, 5G provide fast data connectivity across demanding operational environments.

Turning Material Movements into Actionable Process Data

Every digitally processed transaction also generates data. A scan at goods receiving, a stock transfer or confirmation of an internal transport order does more than document the individual activity. Together, these events create a detailed picture of the actual material flow.

COSYS Business Intelligence transforms this information into dashboards and reports. Warehouse and logistics managers can monitor inventory, order throughput times, transport movements and utilisation and drill down into anomalies. Analyses can extend to individual bookings and material movements.

Forecasting adds a predictive dimension. Historical inventory, movement and sales data can be used to anticipate future demand. For internal supply chains, this means replenishment and resources can be aligned with expected material requirements earlier instead of waiting for shortages or bottlenecks to occur.

Process Mining Reveals How Material Flows Actually Work

While Business Intelligence provides transparency over KPIs, Process Mining examines the processes behind them. Events generated during warehouse and transport operations are combined into event logs using activities, timestamps and unique process references. The software then reconstructs the actual process paths.

This can reveal, for example, that certain transfers regularly take longer than expected, transport orders repeatedly wait at a particular handover point or materials follow unnecessary process loops. Rather than relying solely on a theoretical target process, managers can see how material flows actually behave in day-to-day operations.

This is also where mobile data capture becomes particularly important. The more consistently relevant activities are recorded using the Zebra TC201, the stronger the data foundation becomes for subsequent process analysis.

Keeping Hardware and Software Operational

Within an integrated process chain, the mobile computer becomes part of the operational material flow. Device failures or incorrect application configurations can therefore directly affect data capture and process continuity.

COSYS complements its supply chain software and the Zebra TC201 with MDE Services and COSYS MDM. Devices can be centrally managed, applications and configurations controlled, and the status of the mobile hardware monitored more transparently. Repair, maintenance and other device services additionally help companies keep their mobile infrastructure operational over the long term.

Connect Material Flow Execution with Analysis

A digital material flow is not created by adding a mobile computer or another dashboard in isolation. The decisive factor is connecting operational execution with analysis. COSYS combines supply chain software for warehouse management and IBT with the Zebra TC201 for mobile data capture, complemented by Business Intelligence, forecasting, Process Mining, COSYS MDM and MDE services.

Do you manage material movements between warehouses, production areas or different buildings and want to identify where your internal flows are currently consuming unnecessary time or resources? COSYS can help you select the appropriate software modules and mobile hardware and establish a reliable data foundation for continuous process optimisation. Contact COSYS at vertrieb@cosys.de or +49 5062 900 0.