Simulation and Emulation are key to the Successful Planning of Automated Warehouses

• Simulation is an important key element in the planning phase and is used for early concept evaluation as well as for detailed layout analysis.

• Emulation is used during the implementation phase and enables early end-to-end tests of the goods processes in realistic conditions.

• WAMAS Emulation Center – a test system which enables the customer to modify and test warehouse processes without intervening in ongoing operations.

Reliable decisions from the outset: digital methods create clarity

Simulation and emulation are vital digital methods in future-proof intralogistics. They enable reliability in planning and significantly shorten project life cycles. Empirical values or simple calculations are often insufficient for designing complex storage solutions in an economical way. Moreover, modifications necessary during the construction of a warehouse often result in additional costs and, specifically, delays.

Simulation and emulation models of warehouses thus offer an effective solution: They enable virtual testing and comparison of different warehouse concepts, processes and scenarios within a short time. Warehouse operators can then use this information to decide which warehouse solution and warehouse strategy is the best and ensure rapid commissioning. 

Each technology has its role

Simulation is a crucial tool during the planning phase. Material flow simulations are used both as generic models for early concept validations and as detailed models for precise layout analyses. The focus is on peak days and critical scenarios in order to identify bottlenecks during planning so that layouts and software strategies can be designed accordingly.

The prerequisite for solid planning is that the logistical requirements of the customers are precisely understood. A thorough data analysis is thus carried out at the start of a project. The item master data and order data are checked and figures are calculated for the material flow and for the design of the warehouse areas. This analysis takes account of the predicted business growth of the customer. The graphic platform "LogiVision" enables interactive visualization of item and order structures and of simulation results. This ensures a consistent information flow and enables transparent decisions to be made with the customer.

The findings from the data analysis are carried over to the layout. They are used to create simulation models: generic for quick concept tests or detailed for precise analyses. The Concept Simulation solution developed by SSI SCHAEFER, enables the observation of interactions between warehouse areas over a period of several months. This means that the dimensioning of warehouse areas can be assessed very early on in the project, taking into account specific replenishment strategies.

Simulations provide reliability in planning and clarify workflows. Data-based analyses and simulation-backed findings ensure that the selected logistics solution meets the future requirements of the operator.

In contrast, emulation is used during the implementation phase for the warehouse. Here, the real-life WAMAS Warehouse Management System (WMS) and WAMAS Material Flow System (MFS) software are tested against an emulated system – in other words, against sub-systems not physically running in the warehouse. As the simulation already takes into account WAMAS strategies, the transition from simulation to emulation is correspondingly smooth. Item master data, order data and initial stock data are also transferred from the simulation to the emulation. 

The planning data set is thus also transferred directly to the realization so that the WAMAS strategies can be customized to meet specific customer requirements. When the system is subsequently ramped up, new customer data is transferred from the customer's ERP system on a rolling basis.

All this enables early software end-to-end tests – from goods-in to goods-out: this significantly reduces integration risks, ensures reliable system functionality and enables rapid commissioning with as few iteration loops as possible – for maximum project quality and reliable on-schedule delivery.

WAMAS Emulation Center - the new software solution from SSI SCHAEFER

This solution was developed as the result of feedback from customer meetings which highlighted an ever-growing need for autonomous and independent software tests during the warehouse life cycle. The reason for this is the increasing flexibility required by companies in order to be able to react to new challenges. The WAMAS Emulation Center can analyze and test a wide range of warehouse scenarios at any time, as often as necessary, and without consequences for ongoing operations.

 

About the authors:

Bastian Schumacher studied Industrial Engineering with Logistics at the TU Berlin and also received his doctoral degree in the field of Material Flow Simulation there in 2019. Following a subsequent post-doc phase at the TU Berlin, he moved to SSI SCHAEFER. Today he is Group Director for Data Analysis and Simulation for the company and is responsible for data and simulation-based planning and analysis methods for automated warehouse solutions. He also holds a lectureship at the TU Berlin and is active in specialist groups such as the Arbeitsgemeinschaft Simulation [Simulation Working Group] and the VDI [Association of German Engineers].

Peter Kanonir completed his degree in Engineering in 2003 and since then has held several positions in this industry. His career focus has always been in the field of intralogistics. After working in the automotive industry, he switched to the construction of logistics systems in 2008 and worked in different functions in planning, project management and in sales. He has been working for SSI SCHAEFER for 13 years and over the last 5 years he has held the position of Product Manager for software for material flow systems.