Expansion of the REHAU Logistics Centre, Visbek
SimPlan has successfully completed a project to expand a logistics centre for REHAU.
Initial situation: Validating the planning status for the Visbek site expansion
The task involved a traditional simulation study to validate and verify the planning status for the site expansion in Visbek.
Objective: Managing complex process chains and fluctuating order data
The greatest challenge lay in modelling complex processes and process chains, as well as in dealing with significant fluctuations in order data, which was processed in-house by REHAU.
Solution: Detailed modelling of warehousing, order picking and conveyor systems
The software used was Plant Simulation version 15, together with the SimPlan module set SimSuite / Logistic. The management, analysis and visualisation of the simulation results were carried out using the SimAssist tool. The following were modelled:
- A new automated warehouse area with a high level of detail, including space and stock management
- Several order-picking and service workstations
- Conveyor systems for pallet transport
Results: Target throughput achieved; layout optimised for the future
By expanding workstations and redistributing work tasks, the target throughput was achieved, whilst also saving one load-handling device per stacker crane. In addition, parts of the layout were completely redesigned, enabling a better expansion concept for the future. This provided all those involved with a sound understanding of the future system. Further use of the simulation would also be conceivable in order to be even better prepared for future expansions.
Simulation saves on operating resources and fosters an understanding of the system
The case study demonstrates how a simulation study not only ensures the target performance of an expansion but also reveals concrete savings in operating resources.
