The use of computer simulation in warehouse automation

The use of computer simulation in warehouse automation

Joanna Oleśków-Szłapka1*, Agnieszka Stachowiak1

1
Production Management and Logistics Department
Poznan University of Technology
Poznan, 60-965, Poland

ABSTRACT

The aim of this paper is to present results of the project conducted in the manufacturing company in the furniture
industry. The main objective was to automate the warehouse operation as much as possible and to minimize the
number of staff in the store. The process was modeled using software FlexSim Simulation Software. The proposed
solution reduces the number of used forklift trucks and warehouse workers through automatic insertion and
retrieval pallet racking with stacker cranes. In addition, the range of the production hall to the storage area are
transported by feeder roller (like the storage to the point of completion). All facilities have a chance for long-term
use of their stock in the draft. They also allow for maximum cost savings by manufacturing company while
maintaining full and accurate customer service and their satisfaction with the delivery of the warehouse. In the
future authors want to develop a simulation model with respect to safety stock optimization and optimization of
product location.

1. INTRODUCTION

The furniture industry in spite of the difficult market situation in 2011 reached a record level of production and
sales. It is estimated that a total of micro firms approached it to 30 billion, of which exports accounted for about 27
billion zlotys (about 90% of production sold). Despite the record-breaking results as business situation is very different.
The furniture industry in Poland is highly competitive. The market operates several thousand active players - about
6 000 companies. Entities, which declared the production of furniture as the main activity is more than 23.5 thousand,
including 21 thousand a micro business. However, the share of companies defined as large and medium in the structure
of sales is still for a long time close to 80%. It is these companies largely determine the potential of Polish furniture [9].
The objective of hereby project was to automate the warehouse operation as much as possible and to minimize the
number of staff in the store. Assumptions limit were as follows: 24 hours per day, production volume, finished goods
size, warehouse dimensions, distribution racks in stock, the volume of orders and safety stock.
After analyzing the collected data was selected a ventilation system - heating, electrical installation to the storage of
finished products and the right equipment store: a row pallet racks PHR, stacker cranes, pallet roller conveyor.
Manufacturing company in the furniture industry has been producing covers and sofas. The goal of the company is to
continuously improve efficiency and gain a competitiveness of products produced by the factory. The company
regularly develops its machinery, investing in cutting-edge storage solutions and conducts systematic training program
for their employees.

2. COMPARISON OF FLEXSIM SOFTWARE WITH SIMULATION TOOLS

Nowadays there is a wide range of various simulation tools available on the market for potential users. Among them
there can be mentioned such software as Arena, Promodel, Witness, Automod and FlexSim.
The first four are often seen on the market simulation software. But they have developed a simulation technique from
80 to 90 in the late 1990s, so they have to fall behind. Arena, Witness, Promodel not ternary virtual technology. Virtual
Technology Automod ternary and only wire-frame model (wireframe) representatives, non-real simulation
technology. Some software can only be representative and not actually reflect the real situation. FlexSim it is a
complete 3-D modeling software, in essence, to reflect the actual situation. FlexSim virtual technology less than other

* Corresponding author: Tel.: (0048) 616653401; Fax: (0048) 6653375; E-mail: [email protected]
 Flexible Automation and Intelligent Manufacturing, FAIM2009,Teesside, UK

software. Whether in a simulated drive (engine), statistics analysis, and graphics can reflect on behalf of the situation.
In a simulation analysis, we can obtain real and digital image analysis. In the 3-D virtual FlexSim, users can use the
mouse to zoom and change the visual angle. In other software, is not one. [11]
There are five basic steps to building a model in FlexSim. 1) Develop a layout, 2) Connect objects, 3) Detail the
objects, 4) Run the model, and 5) Review the output.
FlexSim simulation environment is an object-oriented software system used to model, simulate, visualize, and
monitor dynamic-flow process activities. The FlexSim simulation environment consists of the FlexSim compiler, the
FlexSim developer, and FlexSim applications.
This concept makes model building and analysis easier and more powerful. The FlexSim concept also increases
the value and lifecycle of models because Objects are reusable and the models can be used on an operational basis for
either defining or for monitoring real systems. Users can use C++ or flexscript and the internal language for
development or model building. This eliminates the need for users to learn a specialized simulation language that is
not used in other applications. Organizations who (1) Develop simulation products, (2) build models, (3) simulate
models, (4) visualize the relationships of the model’s components, and (5) monitor real-time processes will generate
greater insight and knowledge about their complex and uncertain systems – and success will come to organizations
that have the best information and wield it most effectively.[4]
One of the most venerable and still one of the most frequent, uses of simulation in practice is the simulation of
manufacturing systems [1].
Simulation, once the magic wand of a simulation professional, has the opportunity to become a common tool for
analyzing and solving real-world problems in today’s fast paced, dynamic environment, Seeing the marketplace
changing, simulation software providers began to utilize computer technology to simplify the use of their programs. As
a result, the technology that used to be the realm of experts is starting to be recognized as a tool tahat’s available to a
much wider audience for analyzing and solving real-world problems. From manufacturing to container terminals, from
airport security to emergency response, from mining to health care, simulation technology is making a difference.
Leaders in all sectors of our economy are beginning to realize the value of simulation – not so much as a technology but
as a means to solve problems.[2].
Simulation is often used when the real environment cannot be used or replicated. The real world version might be
too expensive, too dangerous or just impractical to use.[10].
The role of simulation has been known for a long time. However, it’s only been since 1980 that simulation
applications have reached a point where they are truly accessible to a wide range of users. Simulation starts with
modeling and models. A simulation is then puts models in motion. An operating scale model of a piece of equipment is
actually a physical simulation. Modern simulation applications are based on mathematical models but can look physical
as well through three dimensional graphics.
According to D.T. Sturrock [3] when you first think about conducting a simulation study, one of the earliest things
to consider is the project objectives. Why does someone want to simulate this system and what do they expect to get out
of it? To be more specific, you must determine who your stakeholders are and how they define success. Each simulation
must relies on functional specification i.e. what is the model scope and how it shall be detailed.
Topics should include [3]:
− Objectives – summarize from initial high-level objectives what are the problems to solve.
− Level of detail – a model is always just an approximation of reality and can always be improved. It is important
to define the limits of this model, for example the level of detail for a particular model might be suitable for
comparing the relative productivity of alternate designs, but might have insufficient detail to provide a reliable
prediction of absolute system productivity.
− Data requirements – identify what data will be necessary to support the agreed level of detail. Where will this
data come from? Who will be responsible for providing it? When will it be provided?
− Assumptions and Control Logic – summarize how to understand the logic at various points in the system. List of
any assumptions that must be made so that the all stakeholders have a common understanding of how much
detail will be modeled for each part of the system.
− Analysis and Reports –determination who will be involved in the analysis phase of the project. A mock-up of a
final report is an important part of a functional specification. On review of the mockup, the stakeholders will
almost certainly identify things that are missing and things that are unnecessary. It is much better to identify such
items at this point than at the final project presentation.
− Animations – a certain level of animation is generally necessary for model development and validation. In many
cases stakeholders initially may indicate that animation has little importance to them.
− Due Date and Agility – simulation is often a process of discovery. There can be found the new alternatives to
explore and possibly areas of the model requiring more detail. Adequately exploring those areas can potentially
make the project much more valuable. But the best results possible have no value if they are delivered after the
The use of computer simulation in warehouse automation

decision has been made. When are results expected? When is the absolute “drop-dead” date after which the
results will have no value?

Design and operation of warehouses have been subject to numerous research activities and case studies as the
comprehensive surveys by Gu, Goetschalckx, and McGinnis [5], Rouwenhorst et al.[6] and Roodbergen and Vis [7],
Bleifub [8] are showing.

3. PROCESS ANALYSIS AND SIMULATION USING FLEXSIM SOFTWARE

The process in question was modeled using software FlexSim Simulation Software. Simulation was prepared for
the 24 hours working day warehouse. At the beginning of the process packed pallets were going down from the
production line, and the final result is the end of loading vehicles.
The main objective of the simulation is to verify the operation of storage of all proposed solutions.
All production lines for covers work on 3 shifts, 3 lines producing sofas as well, and one production line for sofas work
on 1 shift.
The main objective of the simulation is to verify the operation of storage for all developed solutions.
There is stock maintained in a warehouse to cover 2 week demand. An important requirement was to design a storage
system-based warehouse management system (WMS) and according to the FIFO( first in first out) method. It was based
on data related to the number of covers and sofas manufactured on production lines (volume: 32,945 units within
2 weeks including covers 20,286 units, 12,659 units sofas, a total of 5,462 units of trucks)
Key performance metrics were analyzed: time picker, number of forklifts needed, flow time of finished products.
Considered decision variables: number of employees, number of forklifts, and number of racks and shelves, the number
used at the time loading ramp.
Figure 1 illustrates a scheme by which the flow is finished by the production lines for loading ramp

Production
Racks
lines
Production
lines

Completion zone

Figure 1: The initial model / Object flow diagram

The beginning of the process is packed pallets from the production line, and the end of the loading end cars.
The simulation was carried out for the four production lines, manufacturing sofas AA, AC, AD and covers C. The
period of time considered in the simulation is one day. The aim is to verify the operation of all the storage solutions that
have been developed. Thanks to that the amount of forklifts, needed was identified, as well as custom-picking time, the
amount of trucks and time for loading.
Data was received from the company (table 1)
 Flexible Automation and Intelligent Manufacturing, FAIM2009,Teesside, UK

Table 1: Data from the company

Time of one shift for
covers [min] 420
Time of one shift for The difference is the result of quality issues and complexity of process (sofas are more complex
sofas [min] 400 than covers)
Products per Product Weight Dimensions
product Weight of packed pallete[kg]
pallet [szt.] [mm]
A 60 cover 3,5 1200x800x1100 235,00
B 95 cover 2 1200x800x800 215,00
C 20 cover 5 1200x800x1100 125,00
D 45 cover 4 1200x800x1200 205,00
E 150 cover 1,5 1200x800x1500 250,00
A.A. 2 Sofa 35 1200x800x2200 95,00
A.B. 4 Sofa 17,8 1200x800x900 96,20
A.C. 1 Sofa 69 1200x800x2300 94,00
A.D. 3 Sofa 43,7 1200x800x1600 156,10

Products in bold were used in simulation. For simplification they are called:
• product A.A- sofa type 1
• product A.C- sofa type 2
• product A.D- sofa type 3
• product C- cover type 1

The aim of this work was to automate the warehouse as much as possible. Automation is also associated with the
reduction of the number of staff needed for the stock, which has been achieved. By selecting the appropriate option
simulation, we were able to adjust the time of completion of the contract and determine the best number of forklift
trucks.
The decision concerning resources included:
• 310 cases of 1,5 m cell height and total height 11 m
• 269 cases 2 m cell height and total height 10,5 m
• 501 cases 2,5 m cell height and total height 10,5 m

Designing the warehouse authors considered several solutions. It was possible to use conventional pallet racking,
which staff delivers the goods with forklifts. In this case, however, had a negligible degree of automation in the
warehouse. Another option under consideration was the use of the automatic shelf. This possibility must be ruled out
because the auto racks are designed to hold smaller packaging than the euro pallets.
In the end, the decision was made to purchase an automatic stacker crane, which moves between putting goods on the
shelves designated for this place based on barcodes. Pallets of production facilities will be provided to the stacker
cranes with roller trays and transported the same way to the point of completion. With this solution the number of
forklift trucks used and employees has been significantly reduced because their job is only to provide pallets from the
production site to the tray and the tray to the loading ramp.
FlexSim system simulation was carried out for the four production lines, manufacturing sofas AA, AC, AD and
covers C. The period of time considered in the simulation is one day. The aim was to verify the operation of all the
storage solutions we have proposed. Conceptual model made in the model shown in Figure 2 and 3
The use of computer simulation in warehouse automation

Figure 2: The idea / Flows diagram

Figure 3: Warehouse model in FlexSim

The solution developed gives the company a number of benefits. First of all, it is possible to reduce the number of
staff (3-5 people). Forklift operators will carry the loaded pallets to the production hall of the place of production to the
end of the roll feeder zone and assembling the means of transport (for dock leveler).Internal transportation of pallets is
automated and goes through electric conveyors from production lines to racks and then to completion zones.
If a different number of solutions which run on stock were used trucks would have to be higher because of the need
to put their pallets on racks and their subsequent retrieval. This approach also increases the safety of the work in the
warehouse, which helps to minimize transport traveling in the area.
During the project work appeared necessary to take into account constraints such as the stock kept in reserve (at
stock to cover 2-week demand) and setting spans. The assumed volume of production for two weeks was 32945 pieces
including: 20286 covers, 12659 sofas i.e. 5462 pallets units. Dimensions of warehouse: 40 x 70 x 11,5 meters.
In order to develop simulation model there have been made following operational stipulations: warehouse contains
1100 racks, 5411 pallets places, one shift for covers takes 420 minutes and for sofas 400 minutes, distance between
racks is 1,5 m, trucks do not break down.
Racks had to be placed so as to obtain the largest possible surface storage. It was also necessary to take into account
the number of pallets and their height and to choose the correct size and number of shelves.
Improvement of warehouse logistics has been a very important part of investment process connected with the
extension of buildings and modernization of storage areas. SSI Schaefer proposed an idea based on self-automatic
conveyor system integrated with multi-sector system of mobile racks, served by transporters of reach-truck type.
93 thousands locations of pallets for semi-products and final goods have been divided in three sections of hall.
 Flexible Automation and Intelligent Manufacturing, FAIM2009,Teesside, UK

The crucial role in movement of materials plays electric conveyor for pallets. Decrease of manual transportation either
increase an efficiency or decrease substantially the costs. Customized interface system enables a safe connection with
WMS system.

6. SUMMARY

The aim of the project was to design a warehouse automated as much as possible. The proposed solution reduces the
number of used forklift trucks and warehouse workers through automatic insertion and retrieval pallet racking with
stacker cranes. In addition, the range of the production hall to the storage area are transported by feeder roller (like the
storage to the point of completion). The simulation made it possible to determine whether the treatment adopted will
preserve the timeliness and effectiveness subjected to the analysis process.
All facilities have a chance for long-term use of their stock in the draft. They also allow for maximum cost savings
by Manufacturing company while maintaining full and accurate customer service and their satisfaction with the
delivery of the warehouse.
Warehouse in analyzed company has been also improved and there introduced SSI Schaefer idea of self-automatic
conveyor system integrated with multi-sector system of mobile racks, served by transporters of reach-truck type.
In the future authors want to develop a simulation model with respect to staff availability, safety stock optimization.

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