Experience or simple calculations are often insufficient for effectively designing complex warehouse solutions. However, late adjustments during warehouse construction can be costly. SSI Schäfer addresses this "emulation" —realistic testing even during the construction phase.
Simulation, digital twins, and – of course – intelligenceareartificial currently the most frequently cited tools for describing the advancements in warehouse construction and related processes that lead to improved success rates in the planning and implementation phases. SSI Schäfer contrasts these with the WAMASEmulation Center- end tests – a test system that allows customers to vary and test warehouse operations without interfering with ongoing operations. This significantly shortens project durations.
Preliminary comparison
The simulation and emulation models are designed to allow for the rapid virtual testing and comparison of different warehouse concepts, processes, and scenarios. This enables warehouse operators to make more informed decisions about the best warehouse solution and strategy, and to achieve rapid commissioning.
P. Canonir
A prerequisite for sound planning is understanding the customer's logistical requirements. Therefore, every project begins with a thorough data analysis. Item master data and order information are reviewed, and key performance indicators (KPIs) for material flow and warehouse layout are calculated. The customer's projected business development is also incorporated into this analysis. Item and order structures, as well as simulation results, are interactively visualized using the "LogiVision" . This ensures a consistent level of information and enables transparent decision-making in collaboration with the customer.
Transferred to layout
The insights gained from the data analysis are incorporated into the layout. Based on this, simulation models are created: generic ones for quick concept checks or detailed ones for precise analyses.
Emulation, on the other hand, is already used in the warehouse implementation phase. The real WAMAS Warehouse Management System (WMS) and WAMAS Material Flow System (MFS) software are tested against an emulated system – that is, against systems that are not yet physically operating in the warehouse.
B. Schumacher
Since the simulation already incorporates WAMAS strategies, the transition from simulation to emulation is correspondingly seamless. Additionally, item master data, order data, and initial inventory data are transferred from the simulation to the emulation.
The development of this solution was prompted by feedback from customer discussions, which revealed a steadily growing need for independent software testing throughout the warehouse lifecycle.
Shorten project durations
The background to this is the increasing flexibility that companies need to respond to new challenges. The WAMAS Emulation Center, it is said, allows a wide variety of warehouse scenarios to be analyzed and tested at any time, as often as desired, and without impacting ongoing operations.
B. Schumacher / P. Kanonir
About the authors:
Bastian Schumacher studied industrial engineering with a focus on logistics at TU Berlin and received his doctorate there in 2019 in the field of material flow simulation. After a subsequent postdoctoral phase at TU Berlin, he joined SSI Schäfer. There, he is currently a group leader for data analysis and simulation, responsible for data- and simulation-based planning and analysis methods for automated warehouse solutions. He also holds a teaching position at TU Berlin and is active in professional circles such as the Simulation Working Group and the VDI (Association of German Engineers).
Peter Kanonir graduated with a degree in mechanical engineering in 2003 and subsequently worked in various roles in industry, always focusing on intralogistics. After a stint in the automotive industry, he moved into logistics plant engineering in 2008, where he held various positions in planning, project management, and sales. He has been with SSI Schäfer for 13 years, and for the last 5 years as a product manager for material flow control software.
