FruitMasters: Simulation of transport and buffering system ensures the correct number of AGVs and AMRs
FruitMasters trades in apples and organises their logistics. For the construction of its new warehouse, the company wanted to test the entire transport and buffering system before it opened. This also included Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs). This was the only way to ensure capacity and cost-effectiveness at an early stage.
Initial situation: New warehouse, unanswered questions about the vehicle fleet
FruitMasters planned a transport and buffering system for apples for the new warehouse. It was to consist of conveyor systems, a pool of AGVs and AMRs with a suitable route network, and a high-bay warehouse. As the individual vehicles are very expensive, FruitMasters had to plan the fleet size with particular precision. A fleet that was too small would have hampered throughput and utilisation. A fleet that was too large, on the other hand, would have incurred unnecessary costs.
Objective: To determine key performance indicators and the number of vehicles
FruitMasters wanted to use the simulation to test the planned system before construction began. Specifically, the following questions needed to be addressed:
- What are the throughput, capacity utilisation and cycle times in the planned system?
- Where are bottlenecks likely to occur during operation?
- How many AGVs and AMRs does the system need to reliably handle the planned volumes?
Solution: Layout-based simulation of conveyor systems and route network
SimPlan simulated the planned system based on the expected apple volumes. In doing so, we modelled the relevant conveyor systems, the AGV and AMR fleet—including the route network—and the high-bay warehouse true to the actual layout. This resulted in a model that closely resembles the future warehouse. This accurate representation enabled a realistic simulation of future operational processes, even before the warehouse was commissioned.
Results: Material flows verified, number of vehicles confirmed
The simulation confirmed the planned material flows. It also showed exactly how many AGVs and AMRs the system actually requires. This meant that, even before the opening, it was clear that the system would achieve the intended throughput levels and that the vehicle fleet was neither too large nor too small.
Why simulation is worthwhile before the go-live for new warehouse builds
In new warehouse builds using AGVs and AMRs, actual performance often only becomes apparent during operation if no simulation has been carried out beforehand. That is precisely the risk: every additional vehicle costs money, and every missing vehicle slows down throughput. That is why precise advance planning is worthwhile. Simulation ensures this decision is made correctly before commissioning, rather than having to correct it later whilst the system is in operation.
