The Warehouse Rack Flexsim Simulation System is a tool that uses Flexsim software to model, simulate, and analyze warehouse rack systems. It aims to optimize warehouse layouts, improve operational efficiency, and address potential problems.
Below is a detailed introduction to its core functions and applications:

Core Functions and Application Scenarios

- Storage Capacity Assessment
- Through simulation of parameters such as rack load-bearing capacity, cargo storage density, and turnover rate, verify whether the rack configuration meets requirements, such as optimizing rack height, number of layers, or cargo space allocation.
- Supports modeling and performance comparison of different rack types (such as ordinary upright racks, gravity racks, rotary racks, etc.).

- Layout Optimization and Path Planning
- Simulate the warehousing, out-of-warehouse, and relocation processes of goods, analyze the flow of goods, and identify congestion points or inefficient links.
- Adjust the rack layout (such as aisle width, rack spacing) or equipment configuration (such as stacker crane speed, conveyor belt path) to improve space utilization and operational efficiency.

- Bottleneck Analysis and Problem Diagnosis
- Real-time monitoring of equipment utilization, waiting time, system throughput, and other indicators to locate bottleneck links (such as picking waiting, stacker crane blockage).
- For example, if simulation reveals a blockage in the inbound conveyor belt for a certain type of product, the production rhythm or cargo space allocation can be adjusted accordingly.

- Dynamic Demand Forecasting and Strategy Verification
- Simulate the system's performance under different scenarios (such as a surge in order volume, changes in product types), predict future demand, and develop response strategies.
- Test the feasibility of new processes or equipment, such as the efficiency improvement after introducing automated rotary racks.

Key Technical Implementation

- 3D Modeling and Component Configuration
- Drag and drop rack components, stacker cranes, conveyor belts, etc., in Flexsim, set parameters (such as moving speed, load capacity), and build a 3D model consistent with the actual warehouse proportions.
- Supports custom scripts and logic (such as List, Resource, group) to implement complex operations, such as optimizing the cargo access path of rotary racks.

- Process Logic and Resource Management
- Define the task allocation and operation paths of resources (such as personnel, forklifts), and set the logic of picking, packaging, and shelving through the flowchart editor.
- For example, the temporary storage area monitors the cargo type label, automatically allocates cargo space, and triggers the elevator to accurately place the cargo.

- Data Analysis and Optimization Iteration
- Collect simulation data (such as equipment utilization rate, order fulfillment rate), and evaluate the effectiveness of different schemes through statistical analysis tools.
- For example, after adjusting the stacker crane speed or picking strategy, compare the changes in the system's total throughput to verify the optimization effect.

Typical Application Cases

- Horizontal Rotary Rack Modeling
- Use Motor elements to control the linkage between the conveyor belt and the elevator, simulate the cargo access efficiency when the rack rotates, and is suitable for storage optimization of small-batch, multi-variety materials such as electronic components.
- Key steps include script implementation of temporary storage area monitoring, cargo space retrieval, and precise elevator placement logic.

- Automated Automated Warehouse Simulation
- Integrate stacker cranes, conveyor systems, control systems, and other components to simulate the entire process operation and analyze equipment coordination efficiency and potential blockage risks.
- For example, if simulation reveals that the stacker crane utilization rate for a certain type of product is too low, the task allocation or cargo space merging can be adjusted.

- Distribution Operation Optimization
- Simulate picking, packaging, and shelving processes, optimize picking paths and packaging station layouts, and reduce manual waiting time.
- Supports the configuration of automated conveying equipment, such as directly conveying packaged goods to designated racks.

Advantages and Value

- Risk Reduction: Test new schemes in a virtual environment to avoid the costs and risks of actual modifications.

- Training and Decision Support: Provide simulation operation training for employees and provide data-driven decision-making basis for management.

The Warehouse Rack Flexsim Simulation System, through precise modeling, dynamic analysis, and iterative optimization, helps enterprises improve warehouse efficiency, reduce costs, and adapt to future demand changes.
Its applications range from ordinary rack layout optimization to full-process simulation of complex automated systems, combining flexibility and practicality.