Project:
Warehouse Site Analysis, Simulation and Design
Result:
A model to inform the future state layout and operational requirements to meet the warehouse demand.
1. Problem Statement
- The warehouse needs to accommodate an average of 75 000 “cases” outbound per day which amount to 100 vehicles. Additionally roughly 60 inbound vehicles arrive with new stock daily;
- The large amount of vehicles moving through the site results in congestion – leading to shipment delays;
- Vehicle flow is hindered due to a single gate used for entering and exiting the site;
- The site has limited vehicle parking & staging which overflow into the road – this results in less flow through the site;
- Location of certain key activities contribute to congestion (Wash Bays, Fuel Bowsers & Weighbridges);
2. Solution Approach
- Site Mapping and To-Scale Drawings;
- Site functions, flow and capability analysis;
- Operational baseline and future considerations;
- Gathering and analysis of data relating to current processing times, inbound schedules, outbound throughput, percentage returns and damages, etc.;
- Development and validation of a simulation model of the current system with current business and processing rules;
- Scenario testing involving resource allocation and arrival patterns;
3. Project Outcomes
- Facility design including 3D layout;
- Constraint Analysis and expansion options;
- Future state facility capacity design;
- Delivery of a simulation model representing current site design and flow with scenario testing abilities;
