Simulation
Warehouse Simulation Analysis
Warehouse simulation analysis helps visualize changes in layout and process as
well as answer “what if” questions before implementing automation, Warehouse
Management Systems (WMS) or procedural changes. Warehouse simulation
models can be used to help evaluate potential new automation investments or
even changes to current operations. Results of a warehouse simulation
can help determine throughput rates, the number of employees needed to pick
orders design problems, and system bottlenecks.
A warehouse simulation is an excellent tool to:
- Study the dynamic interactions within the facility
- Model different waving strategies and order grouping options to see impact to operations capabilities
- Identify potential process bottlenecks
- Visualize/communicate automation and process changes to upper management as well as warehouse employees
- Develop benchmark to measure actual performance against
- Evaluate “what if” scenarios
- Estimate overall system throughput and utilization
ASAP Automation’s Warehouse Simulation Process
ASAP Automation uses AutoMod® for model development on warehouse
simulation projects. AutoMod® has CAD like functionality to
define the layout to scale with 3D virtual reality animation for an accurate
graphical representation of the system.
ASAP Automation has developed a well defined five phase approach to performing simulations that includes:
Kick-off Meeting, Collect Data and Define Assumptions
ASAP Automation holds the initial kick off meeting at the
customer site. We study and document the material flow and associated
assumptions for the warehouse simulation project. During the kick
off meeting as much data as possible is collected. An assumptions
document is created to clearly define all the assumptions surrounding
the model including forecast growth and processing requirements. The
objectives and goals of the simulation model are reviewed to ensure
clear project scope and expectations before the warehouse simulation
model is developed.
Develop Base Model
In this step a base line computer model is developed incorporating
the design data and assumptions information collected. The input
data is loaded into the model along with animation of actual processing
operations.
Validate Model
After the base model development is completed, ASAP verifies
proper model execution. That is, ensure that the warehouse simulation
model operates according to the parameters detailed in the Assumptions
document. Production data summaries from the simulation for the
various processes in the baseline configuration are reviewed for accuracy.
Scenario Analysis
Designed scenarios and situations will be used to fully
test the statistical significance of the model meeting the performance
measures. This includes testing the sensitivity of the key system
parameters. These warehouse simulation scenarios determine the
capabilities of the system to meet expected demands of throughput. The
model is initialized with parameters for a base line configuration.
Present Final Results
After all the scenarios have been executed and the output data has been collected, the information is analyzed and summarized into a written report. The final report may include graphs, tables, descriptions and animation videos that document the findings from the simulation. A sensitivity analysis for key parameters may be included where appropriate. The final report will be comprehensive to include all information used to develop the model as documented in the Assumptions document.
Benefits of a Warehouse Simulation
- Increases operational understanding. Realize potential bottlenecks and problem areas though “what if” analysis. Determine up front if a change in processing would improve operations or if new automation is required to support the business changes.
- Reduces Risk. The simulation reduces the risk that the system will not perform as required for your business. Design flaws can be identified and corrected before implementation.
- Visual Tool. Provides a 3D visual representation to help gain confidence in the proposed solution and how the solution will provide benefit.
- Provides validation of design. Acts as a tool to validate design assumptions, manpower requirements and system throughput.
- Insurance policy. Acts as an insurance policy against potential risks.
