Material Handling System Simulations
Warehouse Simulation Analysis
Warehouse simulation analysis helps visualize changes in layout and process as well as answer “what if” questions before implementing automation technology, Warehouse Management Systems 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
Bastian engineers 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.
Bastian Material Handling has developed a well defined five phase approach to performing simulations that includes:
What is a Simulation?
A simulation model:
- is a discrete event, stochastic model of a real or proposed material handling system
- allows to "look ahead" and perform "what-if" scenarios
- solve various operation problems such as equipment layout, asset or resource utilization, etc.
What are the Benefits?
- Risk Mitigation and Cost Avoidance – a better understanding of the overall financial and operational risk inherent in a project will lower contingency planning costs for both the customer and supplier.
- The ability to challenge “What If” Scenarios
- Increased confidence in the final design meeting operational performance measures
- The ability to analyze expected throughput capability
- The identification of process bottlenecks for continuous improvement
- The ability to measure cycle time for specific activities
- The ability to study the dynamic interactions within the facility
- The ability to determine optimum staffing levels in each area
- Avoid costly mistakes – verify design and ensure the material handling system will meet your current and future needs
- Aid in choosing the right material handling system – aids in choosing the right material handling equipment in the design phase
- Validate material handling system design – existing or new designs
- Help with integration to existing systems – ensure complete integration with existing material handling systems
- Provide in depth understanding of your system and business operations – provide insight into your operations
- Establish and verify labor and manning requirements
- Experiment – see how changes to one area of your system affects other areas
What is the Process?
Step 1
- Project Initiation
- Kickoff meeting
- Assignment of committee members
- Begin data collection process
Step 2
- Assumptions Document
- Continue data collection
- Objectives of the model
- Detailed operation description
- Input data requirements
- Project Schedule
- Experimentation to be performed
Step 3
- Base Model Development
- Automod programming
- Detail conveyors and equipment
- Detail resource utilization methodology
- Processes "black-boxed"
- Animation for transport systems
Step 4
- Base Model Validation
- Verify model execution vs assumptions document
- Hands-on demonstration
- Initial data summaries reviewed for accuracy
Step 5
- Model Experimentation
- Run experiments detailed in assumptions document
- Test key system parameters
- Identify potential problem areas
Step 6
- Model Review
- Create base line configuration
- Present and review initial findings
- Present alternative concepts
- Select best alternative
Step 7
- Optimization of Design
- Minor system changes
- Present draft final report
Step 8
- Final Report
- Deliver final presentation
- Includes recommendations
- Comprehensive
Typical Simulation Project Costs & Durations
Small Systems - $5 - 10K- 4 - 6 week duration
Medium Size Systems (Typical) - $20 - 30K
- 6 -10 week duration
Large Systems - $30 - 50K
- 10 - 16 week duration
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1-800-772-0464
