New Hyster simulation software gives warehouses a reality check

Tuesday, 30 September 2008

Warehouse equipment manufacturer Hyster launches a new generation of 3D simulation software for companies seeking to optimise their warehouse and logistics operation.  This follows significant investment by Hyster to deliver the most realistic virtual tool to assist firms with their planning and decision making process to minimise capital risk.

Warehouse simulation software helps companies gain an understanding of how a warehouse would theoretically operate, whether for a new development or changes to an existing operation. 

Robert O'Donoghue, General Manager for Hyster's Warehouse Products, explains: "Simulation is not an exact science, however it can provide a realistic indication of the viability of various fleet options.  Warehouse managers will be able to consider different fleet mix scenarios and develop a good idea of potential pallet throughputs and related costs."

A Hyster warehouse expert will work with a customer to input all the relevant data for their operation.  Key data will include the normal arrival and dispatch patterns with estimations of the minimum, average and maximum number of pallets per load.  The expert will also require data on the size of the warehouse, racking dimensions, and the number of loading and unloading bays.  Using this data, he can then develop scenarios based on varying the number and types of materials handling equipment. 

A series of algorithms, based on the known performance parameters of each truck will then illustrate how the warehouse would actually work.

Hyster has invested significantly in developing the software with Incontrol Simulation Software BV.  The software has been developed to provide the most accurate representation of warehousing operations available from a materials handling provider.
   
The need for realism has been a key consideration in the development of the warehouse simulator.  Each simulation takes into account significant details of the warehouse operation:
- Battery discharge, re-charging, changing times and rates
- Dwell and Radio Data Terminal access times
- Operator shift patterns, break times and ability/permission to drive certain truck types
- Creep speed when forks are lifted
- The degree of truck slow down when cornering or when near another truck.

The programme can also simulate a variety of order picking methods and will show in clear graphical form where and when congestion occurs.

Robert O'Donoghue continues: "We developed the software based on our significant experience of what actually happens in warehouse operations. It was important to make sure that we included all available information to provide an accurate picture of how a materials handling fleet would perform."

The warehouse simulator enables the customer to view 2D and 3D representations of their operation. It also provides a series of graphs illustrating the utilisation and throughput of each operational area throughout the day.  Hyster specialists, trained specifically on the system, then help to identify the optimum fleet mix to maximise productivity and minimise the total cost of the warehouse operation.

"The simulator allows the warehouse owner to know if he really has the right mix of trucks. The Hyster warehouse simulator can vividly demonstrate how the selection of a slightly different mix of trucks can reduce cost and improve overall efficiency."

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