Warehouse Simulation Modeler
Overview
The Warehouse Simulation Modeler provides discrete event simulation capabilities for warehouse design validation and capacity planning. It models warehouse processes, identifies bottlenecks, and evaluates scenarios to support investment decisions and operational improvements.
Capabilities
- Process Flow Simulation: Simulate end-to-end warehouse processes including receiving, putaway, picking, packing, and shipping
- Bottleneck Identification: Identify process bottlenecks and constraints limiting throughput
- Capacity Scenario Modeling: Model capacity under different demand scenarios and operational assumptions
- Equipment Utilization Analysis: Analyze utilization of material handling equipment and identify optimization opportunities
- Labor Requirement Forecasting: Forecast labor requirements based on volume projections and process models
- Layout Optimization Testing: Test and compare warehouse layout alternatives through simulation
- ROI Calculation for Automation: Calculate return on investment for automation and technology investments
Tools and Libraries
- SimPy
- AnyLogic
- FlexSim
- Arena
- Python Simulation Libraries
Used By Processes
- Slotting Optimization
- Warehouse Labor Management
- Pick-Pack-Ship Operations
Usage
skill: warehouse-simulation-modeler
inputs:
warehouse:
facility_id: "DC001"
square_footage: 250000
layout:
receiving_docks: 10
shipping_docks: 15
pick_modules: 3
storage_racks: 5000
processes:
receiving:
pallets_per_hour: 50
putaway_time_minutes: 8
picking:
lines_per_hour: 45
zones: 4
packing:
orders_per_hour: 30
stations: 10
shipping:
pallets_per_hour: 60
resources:
forklifts: 15
pickers: 40
packers: 25
scenarios:
- name: "Current State"
daily_orders: 5000
daily_inbound_pallets: 200
- name: "Peak Season"
daily_orders: 8500
daily_inbound_pallets: 350
- name: "With Automation"
daily_orders: 8500
automation:
goods_to_person: true
auto_packing: true
outputs:
simulation_results:
- scenario: "Current State"
throughput:
orders_completed: 5000
completion_rate: 100
average_cycle_time_hours: 4.2
utilization:
forklifts: 72
pickers: 85
packers: 78
receiving_docks: 65
shipping_docks: 70
bottlenecks: []
- scenario: "Peak Season"
throughput:
orders_completed: 7200
completion_rate: 84.7
average_cycle_time_hours: 8.5
utilization:
forklifts: 95
pickers: 98
packers: 92
receiving_docks: 90
shipping_docks: 95
bottlenecks:
- resource: "pickers"
constraint: "capacity"
impact: "15% orders delayed"
- resource: "shipping_docks"
constraint: "capacity"
impact: "carrier wait times increased"
- scenario: "With Automation"
throughput:
orders_completed: 8500
completion_rate: 100
average_cycle_time_hours: 3.8
utilization:
goods_to_person_system: 82
auto_packers: 75
shipping_docks: 85
bottlenecks: []
investment_analysis:
automation_investment: 5500000
annual_labor_savings: 1800000
throughput_increase: 18
payback_period_years: 3.1
five_year_roi: 64
recommendations:
- "Current capacity sufficient for baseline demand"
- "Peak season requires 12 additional pickers or automation investment"
- "Automation investment justified with 3.1 year payback"
- "Consider adding 2 shipping docks for peak flexibility"
Integration Points
- Warehouse Management Systems (WMS)
- Enterprise Resource Planning (ERP)
- CAD Systems (for layout)
- Financial Planning Systems
- Labor Management Systems
Performance Metrics
- Simulation accuracy
- Throughput capacity
- Resource utilization
- Bottleneck identification
- Investment ROI accuracy