Warehouse simulation: "The benefits of optimisation"
Warehouse simulation: "The benefits of optimisation"

Warehouse simulation: "The benefits of optimisation"

Simuation allows your organisation to focus on improving time utilisation and cost management by duplicating your existing operation to enable virtual testing risk free.

Efficiency can be maximised by introducing more variables to your model such as resources, tasks, processes, equipment and inventory to optimise the flow of your business. The approach can be broad to incorporate an entire supply chain or specific to a warehouse operation where we simulate core functional areas. Gains of up to 50% can be achieved on certain processes by eliminating delays and unnecesary steps. Balancing cost against service becomes much easier for a warehouse manager.

Why simulate your warehouse operation?

Supply chain and logistics managers typically approach problem solving in a linear manner and concentrate on core areas using specific analysis tools to improve performance. Simulation allows all of the processes to be connected creating decision support solutions that drive business performance. For your warehouse simulation the benefits of optimisation will be discussed in detail.

3D animation
Imaging being able to view your entire supply chain as a visual 3D model with rich 3D objects that make your simulation as real as the operational environment you work in. Imaging being able to see your operators process orders, pack cartons and despatch these to your customers. 3D allows you to create a virtual model of a recieving process where all of your inbound deliveries are processed, look at the time taken and then make changes to improve the cycletime
Ease of use
Models are able to be created in minutes working alongside our supply chain consultant who's experience in supply chain operations can simplify the process. Create objects with the use of drop down functionality and develop processes within minutes so you can see how efficiently products move within your warehouse simulation.
No limit to detail
The opporunities to construct warehouse simulation models is left to your desire to reach the level of detail needed to improve process workflows, reduce cycle time or increase efficiency. You may choose to construct your warehouse simulation at a high level where resources, equipment and pallets are visible throughout your warehouse operation with each assigned timings and costs. Alternatively, you may wish to manage inventory to an sku level to influence the real level of inventory investment.
Project scope
Our supply chain consultants are able to work with you to define the project scope for your warehouse simulation project. Our experience in working on simple or complex supply chain projects will add value to your organisation and provide a level of transparency for scope creep to be acommodated. Core functions such as receiving, unloading trucks, sortation, put-away, replenishment, slotting, picking and despatch are able to be constructed with ease.

What areas of a warehouse can be simulated?

Inbound logistics

Manage your daily receiving function by monitoring all workflow processes responsible for the processing and release of inventory into your warehouse facility. If demand is too high for some parts of the receiving operation, you can simply redistribute resources to speed up the booking in process and make stock available for customer orders. Utilise all of your materials handling equipment to meet the delivery schedules for your operation. Deal with unplanned deliveries by allocating resources from another area to assist with the processing of the delivery. Manage the flow of containers and trucks into your facility by improving the layout controls of your site.

Staging area

Each warehouse operation tends to suffer from a lack of dedicate space for placing inventory to be processed or in readiness for direct put away into a bulk or pick location. By simulating the flow of materials throughout the front end of your operation, opportunities will be created to better utilise flow and storage for your deliveries, customer returns or inventory staging. Allocate resources to balance the flow and control the cycletime to the next operation.


This process is the final stage of the receiving operation and needs to be managed on a daily basis to ensure that stock is available for the picking process. By constructing an inventory based simulation model, deliveries can be directed to specific bulk or pick locations which will allow for better resource utilisation and control of your casual resource budget.


Utilise your resources throughout the day and night by better managing the customer order requirements with your replenishment team. Our aim is to ensure that stock is available in the pick faces or bulk positions in readiness for the next wave of customer orders. A simulation model will help you balance labour against volume and timeframes by modifying allocation parameters, cost, shift times and wave picking sequences.


Large warehouse operations can have over 50 resources who are picking customer orders for local and national distribution. Shifts and start times are often staggered to balance customer demand requirements with available resources. Simulation offers the opportunity of helping improve resource utilisation levels, allocation to specific tasks that need to be completed and the ability to manage your resouce plan more effectively. Whether you are using wave picking, voice picking, RF picking or manual paper based picking, each process and technology enabler can be simulated to provide you the opportunity of optimising picking.

Warehouse simulation: "The benefits of optimisation"

  • Ability to flex a warehouse operation to support non seasonal demand fluctuations.
  • Improved resource utilisation and cost containment
  • Increased asset utilisation to ensure your investment is maximised
  • Ability to introduce layout and goods flow changes to your warehouse operation
  • What if cost versus service scenarions for improved supply chain performance
  • Cost versus time savings are more identifiable and visible
  • Greater responsiveness to changes in customer demands

Warehouse simulation: "The benefits of optimisation"