Putting warehouses to the (digital) test: how do simulations work?

With warehouses both big and small, the goals are largely the same: precisely coordinated processes, seamless material flows and the best-possible utilization of available vehicles. Automated vehicles add a further layer of capability – but also complexity. How do you determine which route is the most efficient, when and how many vehicles are needed to receive incoming goods, or how to best combine automated and manual tasks? Simulation software provides the answers to these and many more questions.

What is a simulation? According to one definition: “a model of a real activity, created for training purposes or to solve a problem.” But how exactly do these digital copies of real-world processes, events, etc. actually work? In the case of warehouses, the simulation is a faithful replica of its real-life counterpart, created by means of corresponding software. Simulated processes and vehicles can be controlled and adjusted accordingly. “In simulations, we can examine diverse variables by means of software, and determine how to best tailor processes – both in advance, during the planning phase, and when evaluating existing warehouses”, explains Nadine Scheuermann, Automated Solutions Team at Linde Material Handling.

The key benefit: simulations allow warehouse operators to initially try out changes to processes in a digital space – and not the real world. In other words, customers’ actual orders do not need to become “guinea pigs.” Instead, with the aid of smart software, it is possible to take a closer look at critical areas. These include the goods receiving department, where trucks unload pallets, plus loading points and warehouse intersections. Material flows can be planned, tested and, above all, improved in great detail.

Reducing complexity, raising efficiency

“Once the simulation model has been established, it is refined until we have the best possible version of the target process,” adds Moritz Büttner, also of the Automated Solutions Team at Linde Material Handling.

“Generally, simulations help ensure the routes vehicles take through the warehouse are seamlessly coordinated, and that there is no congestion or gridlocks –where two or more AGVs end up blocking each other, for example at an intersection, bringing movements to a complete halt.”

Simulations also assist with planning vehicle deployment. For instance, vehicles that are currently idle and waiting unproductively at parking positions can be relocated, where appropriate. Furthermore, simulations can help with ensuring the best possible utilization of charging stations.

Leveraging digital tools to plan ahead

The simulation tool employed by intralogistics expert Linde Material Handling is based on a digital map that replicates the actual layout of the customer warehouse. It visualizes all key junctions, planned routes, loading points and parking positions. “Automatic doors, bridges, bottlenecks – all these features can be simulated to determine what effect they have on performance,” explains Moritz Büttner.

Best prepared

The goal is to gain reliable, actionable data. Simulation makes it possible to precisely assess what can be shipped where and when by means of a defined number of vehicles. Trips with and without loads, power consumption, charging times and idle time – the software can use these dynamic parameters to paint a realistic picture of reality. However, according to Scheuermann, you need at least eight hours of simulation to arrive at meaningful results.