Simulation Provides a "Crystal Ball" for Client to Modernize their Retail Fulfillment Center

We recently teamed up with Berkshire Grey to help a US-based retail client modernize their fulfillment system featuring BG's RSPS technology. This client, like many, has unique product, volume, and order characteristics.

Simulation provided a crystal ball to future system performance. We were able to identify and remedy several logic and mechanical bottlenecks while it was still inexpensive to do so. We also supported sensitivity testing of future volume mixes to build confidence that the investment could meet the current and future needs of our client. Finally, our focus included optimizing for headcount. We developed and tested creative techniques to improve the utilization and productivity of the human workforce.

VIDEO TRANSCRIPT

In order to meet growing demand, a major US retailer partnered with Automation Intelligence and Berkshire Grey to create a simulation model that could optimize their complex order fulfillment facility.

This system is designed to handle over 20,000 picks per hour for over 1000 downstream stores during peak weeks.

Our goal was to thoroughly vet the warehouse design by stress-testing a simulated model of the system in various scenarios. This process identifies potential issues so that our client can cost-effectively resolve them early in the design process.

We focused on the intricate logic of the warehouse design. The simulation accurately represents real-world conditions, from conveyor speeds to assignment algorithms and operator capacity.

Our model provided data-driven insights. We analyzed station utilization, conveyor capacities, storage, buffer utilization, and process speeds so that our client could use scientific results to make key capital decisions.

Labor optimization was also crucial for this project. We tracked operator utilization and developed strategies to maximize capacity without degrading performance.

In our experience, simulation is an essential part of the design process. With our partners Berkshire Gray, we were able to ensure that our client has a robust, highly functional system that can handle even the busiest days of the year.

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