Warehouse and logistics centre simulator software

By creating a digital twin of the warehouse, efficiency, order preparation, replenishment, location allocation, and storage methods can be optimised. The warehouse simulation software allows you to design a new warehouse, optimise an existing one, or plan automation and capacity forecasting. By connecting the warehouse simulation software to the SGA systems existing systems, continuous analysis of picking strategies, labour requirements and wave release schedules can be performed. In addition, the warehouse simulation software enables analysis and validation of automation deployment, AGV/STV implementation, and ASRS capacity and capabilities.

Advantages of using warehouse simulation software

• Increased warehouse efficiency
• Transport design and optimisation
• Optimisation of materials handling and fleet sizing
• ASRS, AGV and STV capacity planning
• Design and layout of facilities
• Analysis of the distribution centre network
• Congestion analysis and reduction
• Validation and automation design
• Interaction between people and automated equipment
• Capacity planning and scheduling

The use of a warehouse simulation software It can also help analyse the impact of future warehouse growth and identify potential capacity constraints. Warehouse optimisation is easy to control, and what-if analysis can be used to determine the potential impact of new flows and equipment on operations.

Another key aspect that influences warehouse efficiency is congestion at various points in the environment. It is possible to simulate and optimise the analysis of congestion of incoming and outgoing forklifts, internal picking sequences and replenishment schedules to improve efficiency and reduce the overall cost of the operation.

• Warehouse simulator software for generating heat maps, spaghetti diagrams, congestion maps, and storage density analysis.

  The use of a warehouse simulation software serves for the iImporting the current inventory by SKU and location, as well as importing or generating picking, storage, and replenishment sequences. The model runs and all maps are generated automatically, allowing you to compare different temporary heat maps, congestion maps, and storage density analyses based on different time intervals.

• Warehouse simulator software to optimise stock distribution

  The use of warehouse simulation software It can be applied to new and existing warehouses to achieve a more flexible stock distribution, characterised by the following:

  • Importing locations, SKUs, and restrictions.
  • Allocation of locations based on speed, congestion, weight, dimensions, etc.
  • Prioritisation of locations by strike zones, preferred picking locations, and lifting restrictions.
  • Organisation by product type, category or manufacturer.
  • Generation of optimised regrouping movement sequences and work instructions.
• Warehouse simulator software for distribution centre simulation

  The use of warehouse simulation software Applied to distribution centres, it enables the following:

  • Elimination of multiple storage areas, reduction in time spent receiving and storing incoming inventory.
  • Improvement of replenishment schedules to eliminate waiting times at the picking line, thereby reducing delays in the checking area.
  • Identify the necessary labour requirements and analyse the potential benefits of existing automation technology.
  • Identify, analyse, and mitigate the limitations imposed by possible slot allocation strategies.
  • Impact on physical facilities: Expand and modify the layout, as well as optimise the layout of a new facility.
  • Identify the impact of facility design on overall warehouse efficiency.
  • Minimise movements, arrangement of conveyors, optimisation of mergers.

  Did you know that Industry 4.0 offers solutions for optimising warehouse operations? Discover the benefits of using Warehouse robots: Types, uses, and applications.

• Warehouse simulator software for distribution centre optimisation

  Thanks to the capacity of the warehouse simulation software To interact dynamically with external data, companies have successfully implemented simulation to analyse the location of warehouses and distribution centres in relation to demand. Product allocation is no longer a guessing game, but a simulated science that simplifies one of the most complex problems in this industry.

Main reasons for using warehouse simulation software

Many people do not understand the true value of simulation and do not explore the implications of operational changes or how the addition of new equipment, systems, and software will affect warehouse productivity.

The first step is to determine whether the warehouse simulation software is the right tool. Many experts agree that simulation should be used when introducing new processes. This applies to complex or high-volume picking environments that require components to be gathered in the consolidation area at the right time, or when implementing new warehouse management system rules in a high-volume facility with delivery deadlines.

The warehouse simulation software is not the right tool for all warehouse design or redesign projects. Therefore, you need to define the problem and decide whether simulation is the solution to solve it. The warehouse simulation software It is not the right tool for facilities with simple processes, low volume, no deadline issues, where no new equipment is introduced or used differently, or where warehouse processes are not modified.

Next, let's look at the main reasons for using a warehouse simulation software:

• Warehouse simulator software for proof of concept

  The warehouse simulation software It is very suitable for showing how an automated material handling system will work and for determining performance and rates. In a project for a major technology company, the team used simulation to show how the new packing benches would work with an inserter/extractor carousel. As this was a new concept for the company, there were no similar examples to draw on, so they resorted to using a warehouse simulation software to demonstrate how it would work.

  Once the model has been created, it is easy to see what would happen in different scenarios. With a warehouse simulator softwareDifferent variables, such as labour, can be added to the model. By changing one variable, the company discovered the optimal number of employees it would need at different carousels to increase the number of orders it processed each day from 1,200 to 2,000.

  Simulations detect design flaws that can only appear when the system is in use. In the case of this company, before the fault appeared, a random storage system model with one week's worth of data was used. The system used 32 different carousels, which caused too many containers to be fed into the system. It was changed to another random storage system that reduced the load on the conveyor system.

• Warehouse simulator software for greater commitment from managers and employees

  It is much easier to sell an idea or concept when it can be visualised. The warehouse simulation software It was a good way to show management how incorporating a conveyor system and software would improve the business. He showed simulations of the project to hesitant employees. In fact, there was a simulation of someone standing at a workstation that demonstrated what the work would be and where the trolley would be located. Once they saw this simulation, they realised they had a role to play in the new facilities.

  The warehouse simulation software is used to create simulations that collect a lot of data. This data is very useful when selling a concept to executives. However, you have to collect and present the right data, because the success of the project depends on those figures. Executives will want to know the number of lines, capacities, yields, rates, and monetary values. A simulation can provide them with this information.

• Warehouse simulator software to optimise operational and business rules

  Simple simulation of equipment and material flows has nothing to do with the real needs of companies. Simulation can be taken to the next level with a warehouse simulation software y overlaying operational procedures and business rules onto equipment simulations. This type of simulation shows companies how and whether warehouse designs meet their business requirements. Running tests with the model shows what the rules will actually do. Since this type of simulation requires more expertise, time, and involvement, many companies do not take the time to create the model.

• Warehouse simulator software to optimise the control system

  The value of modelling with a warehouse simulation software arises when companies model the business rules integrated into the warehouse management system that controls their processes. Sometimes, the failures revealed by the simulation are actually found in the control systems or operating procedures. Generally, this part of the design process is not given as much consideration as the layout prior to commissioning. It is very useful for customers to think through and define their operating rules and control processes before creating a model that incorporates those rules. The result is more useful and realistic and can be used to simulate the impact of their warehouse management system.

  For example, an SGA makes decisions about grouping and releasing items. These decisions can be reduced to a relatively simple set of control system rules that can be implemented in a model showing how they will affect operational performance and productivity.

  Companies implementing ERP systems are concerned about how they will affect their SGA. The impact can be simulated, and it all depends on the operating rules that the SGA will apply. It is really easy to simulate and has a potentially huge impact in terms of system performance. Do you need some tips for implementing an SGA system?

• Warehouse simulator software to revalidate the design

  A warehouse simulation is usually used once and then discarded. However, they are much more valuable if managers revive them and use them from time to time. After all, facilities and companies change. The changes that occur after a simulation with warehouse simulation software can cause bottlenecks and reduce productivity and capacity. Managers do not think to re-analyse what the impact of the change might be. Some customers request a simulation tool with a simple user interface that allows them to make updates to check whether the addition of new equipment will have any impact.

Tomec offers companies the Emulate 3D simulator software, a virtual commissioning system that acts as an integrator for the automation of production lines for logistics and distribution centres. This results in better systems, as the emulation of PLC programmes in automated production lines for logistics and distribution centres allows for more comprehensive testing using a precise dynamic digital twin of the actual system before the project is launched, which translates into cost savings compared to traditional techniques.