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Modeling equipment, processes and rules help to optimize warehouse productivity.
Simulation is a powerful warehouse design tool. It can help managers visualize facility layouts, answer "what if questions, and demonstrate the effectiveness of a new design or process. But, it can do more.
"Many people miss the real value of simulation because they don't take it far enough," says Randall Gibson, president of Automation Associates, Inc. (Solana Beach, Calif.). They fail to explore the implications of operational changes and how the addition of new equipment, systems and software will impact the productivity of a warehouse.
The first step is to determine if simulation is the correct tool to use. Many experts agree simulation should be used when new processes are introduced; if it is a high-volume or complex picking environment that requires components to come together at the consolidation area at the right time; when new rules from a WMS system are being implemented; and in a high-volume facility where there are deadlines. Simulation is not the right tool for every warehouse design or redesign project.
"You need to define what the problem is and decide if simulation is the solution to help solve the problem," says Donald E. Kuzma, president, Trommer & Associates Inc. (Akron). It is not the right tool, he says, for facilities with straightforward processes; low volume; no timing issues; no new equipment being introduced or equipment being used differently; or when the warehouse's processes are not being changed.
Here are the top five reasons for using simulation software:
1. Proof of Concept
Simulation is well suited for showing...