Warehouse Simulation

Project Report-1
BY
AMEY AGARWAL 2019B4AB0731P
KARTIK ANEJA 2019A4PS0595P
RISHAB KABDI JAIN 2019A4PS0525P
TARAN CHAUDHARY 2019A4PS0190G

AT

(CCS Strategy Solutions - FlexSim, New Delhi)

A Practice School-I Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

(May-June 2021)
 A REPORT

ON

(Title of the Project in Capital Letters)

By
Name (s) of the student ( s) ID No.(s)

AMEY AGARWAL 2019B4AB0731P

KARTIK ANEJA 2019A4PS0595P

RISHAB KABDI JAIN 2019A4PS0525P

TARAN CHAUDHARY 2019A4PS0190G

AT

(CCS Strategy Solutions - FlexSim, New Delhi)

A Practice School-I Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

(May-June 2021)
 A REPORT
ON
INCREASING THE RATIO ON NUMBER OF SATISIFIED ORDERS TO THE
NUMBER OF UNSATISIFIED ORDERS AND TO IDENTIFY THE POTENTIAL
BOTTLENECKS IN CURRENT WAREHOUSE SIMULATION DESIGN

BY
Name of the student (s) ID No.(s) Discipline(s)

Amey Agarwal 2019B4AB0731P B.E.(HONS.) MANUFACTURING

Kartik Aneja 2019A4PS0595P B.E.(HONS.) MECHANICAL
Rishab Kabdi Jain 2019A4PS0525P B.E.(HONS.) MECHANICAL

Taran Chaudhary 2019A4PS0190G B.E.(HONS.) MECHANICAL

Prepared in partial fulfillment of the

Practice School-I Course Nos.

BITS F221
AT

(CCS Strategy Solutions - FlexSim, New Delhi)

A Practice School-I Station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

(May-June 2021)
 ACKNOWLEDGEMENTS
In the present world of competition, there is always a race between
people to succeed, in which those who have the will to come forward
and accept challenges undoubtedly move ahead. The projects are like
a bridge between theoretical and practical learning. With this willing
and high spirit, we joined this project and had a valuable learning
experience. First, we would like to thank the Almighty God, who
guided us to work on the right path of life. Next to him are our Parents,
without whose constant motivation, this project would not be a reality.
We would like to extend our sincere gratitude to Dr. Sudeep Kumar
Pradhan, Assistant Professor, Mechanical and Manufacturing
Department and Mr. Arun K.R, Simulation Manager, CCS Strategy
Solutions for providing us with the opportunity to work under this
Practice School project. We thank them for their continuous and
persistent guidance without which this project would not have been
possible and for providing us with the knowledge to understand the
intricacies involved in simulation of automated layout manufacturing.
I would also like to extend my heartfelt gratitude to Prof. Srinivasa
Prakash Regalla (Instructor In-Charge, Practice School Division, Birla
Institute of Technology and Science, Pilani Campus) and all the other
Members of Practice School Division for their generous and friendly
attitude
 ABSTRACT
BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE PILANI (RAJASTHAN)
Practice School Division

Station: CCS Strategy Solutions - FlexSim, Centre: New Delhi

Duration: 28 days Date of Start: 01-06-2021

Date of Submission: 28 June 2021

Name(s) and designation(s) of the expert(s): Dr. Sudeep Kumar Pradhan,
Assistant Professor, Mechanical and Manufacturing Department
Name(s) of the PS Faculty: Mr. Arun K.R, Simulation Manager, CCS Strategy
Solutions
Title of the Project: Analyzing and improving upon the effectiveness of the
present warehouse design before implement
Project Areas: Supply Chain Logistics Simulation, Data Analysis,
Warehousing, Inventory Management
Key Words: Simulation, Analysis, Lean Manufacturing, Six Sigma, etc.
Abstract: The Purpose of this project is to determine the number of the
satisfied and unsatisfied orders in the current warehouse design considering
the inbound and outbound material handling logistics over a time horizon of 3
months. The primary motive of this report is to assess how the efficiency and
effectiveness can be improved further in the present design and to identify
potential bottle necks and to provide appropriate recommendations to get rid
of it. Thorough analyzation of data has been performed to improve the
effectiveness of the design.
 Response Option Sheet
Station: CCS Strategy Solutions - FLEXSIM
Center: NEW DELHI

Name(s) of the student(s) ID. No.(s) Discipline(s)

AMEY AGARWAL 2019B4A40731P B.E.(HONS.) MANUFACTURING

ENGINEERING
KARTIK ANEJA 2019A4PS0595P B.E.(HONS.) MANUFACTURING
ENGINEERING
RISHAB KABDI JAIN 2019A4PS0525P B.E.(HONS.) MECHANICAL
ENGINEERING
TARAN CHAUDHARY 2019A4PS0190G B.E.(HONS.) MECHANICAL
ENGINEERING

Title of the Project: Warehouse Simulation

Usefulness of the project to the on-campus courses of study in various

disciplines. Project should be scrutinized keeping in view the following
response options. Write Course No. and Course Name against the option
under which the project comes.
Refer Bulletin for Course No. and Course Name.

Code No. Response Option Course No.(s) & Name

1. A new course can be designed out of this -

project
2. The project can help modification of 1) MF F219 – Operations
The Management
course content of some of the 2) ME F316 – Manufacturing
Management
existing Courses
3. The project can be used directly in some of -
the existing Compulsory Discipline
Courses (CDC)/ Discipline Courses Other
than Compulsory (DCOC)/ Emerging Area
(EA), etc.
Courses
4. The project can be used in -
Science (ES)/ Technical Art (TA) and Preparatory
Core courses like Analysis and Application
Courses Oriented Courses (AAOC)/
Engineering
5. This project cannot come under any -
of the
above mentioned options as it relates
to the professional work of the host
organization
 TABLE OF CONTENTS

CONTENT PAGE NO.

Acknowledgements 4

Abstract 5

Introduction & Methodology/Approach 8

Main Body 10

Observations & Conclusions 13

References 14

TABLE OF CONTENTS
Acknowledgements ……………………………………………………………………………
Abstract ……………………………………………………………………………………………..
Introduction ……………………………………………………………………………………….
Methodology ..……………………………………………………………………………………
Main body ………………………………………………………………………………………….
1. Present-Design: Statistics, Port Connections, Speed of Processing,
Supply(Arrival) Rate of material
2. Getting Data from the Model: Dashboard Creation, Chart Making,
Custom Statistics Collector, Analyzing the data
3. Finding major flaws: Reducing the unsatisfied orders, identifying
potential bottlenecks.

Observations and Conclusions ………………………………..………………………….

References…………………………………………………………………………………………..
 INTRODUCTION
The warehousing operation is an integral part of the total supply chain process and creates a
clearly defined break point between the supply and demand aspects of any business. The
operation involves the holding of materials and goods at various points in the supply chain from
inbound through to the ultimate out bounding and beyond to the consumer. The objective of
the operation is to ensure materials and goods are kept in the required condition and are
available for movement (transport) to the next stage in the supply chain.

Historically, the physical nature of the business has emphasized the labor-intensive nature of the
activity, calling for a high level of man-management and control. However, the significant
advance in technological support in both the physical and administrative aspects of the
operation, has resulted in an increasing degree of the operation becoming “system” driven.

This advance, together with a more pro-active rather than reactive approach, has emphasized an
increased need for improved planning and operational management.

There are several reasons for having a warehouse, the main reasons are:-
• Stockpiling – The warehouse acts as a buffer between supply and demand, a function
which becomes especially important when seasonality is involved.

• Production – Warehousing is needed for the storage of raw materials, components, sub-
assemblies, work in progress and finished goods, to achieve economies in the production
process.

• Product Mixing – To provide a facility for combining several products into a new one
through a packaging operation.

• Consolidation – The warehouse acts as a consolidation point to ‘pull’ product from

suppliers into a location, which sorts and then moves to the final customer. This
warehouse can be for sortation only with no stock being held.

• Distribution – The warehouse network allows products to be ‘pushed’ from the

manufacturer through the network to the end user.

• Customer Service – The warehouse is there to provide the desired service level, which
principally will be delivery time.
By doing literature reviews on previously developed designs on the similar grounds
and assumptions as well as by enhancing it by our own vision and intuition, this
report has been created.

METHODOLOGY/APPROACH
The selected warehouse in this study serves as a distribution center with
variations in product types and demands. There are different racks working for
different products. The warehouse operates as one single processing unit,
which consists of sequence of activities. The major concern of the warehouse
is to reduce the reduce the unhappy deliveries and so their contribution in the
total products produced. So, we have divided the methodology in the
following steps/procedures

1. Preparing the well-structured model as given in the problem statement

2. Preparing graphs and charts on the present model

3. Collecting valuable information from the data gathered from graphs

4. Applying mathematical and statistical methods to improve the efficiency

of the model

5. Making an entirely new model based on the requirement of the industry.

6. Writing down the bottlenecks found by comparing both the models

 MAIN BODY
STEPS TO BE TAKEN FOR THIS APPROACH:

1. Present-Design: Statistics, Port Connections, Speed of Processing,

Supply(Arrival) Rate of material

A 3D Model has been formed by the given data in FlexSim using various tools
such as source, queue, sink, etc. They have been connected through port
connections. All timings have been set in minutes and the inbound truck
arrives with an inter arrival time of 30 mins and in each delivery 5 packages
are delivered at the inbound area. The order arrives every 30 mins and in each
order 5 delivery packages are sent outbound.

Given Layout:
Fully Developed Model:
 2. Getting Data from the Model: Dashboard Creation, Chart Making,
Custom Statistics Collector, Analyzing the data

Since the purpose of building this simulation model is to make the current
warehouse design more efficient and to increase the number of satisfied
orders, we have gathered data with the purpose of answering the following
questions:

• How long does the stockpile up get at various points during the
simulation?
• What is the average amount of time that an order spends going through
the process?
• How many orders are leaving feeling satisfied or unsatisfied?
• What percentage of the time is the model busy managing the warehouse
(as opposed to being idle)?
This data is then analyzed from a more intuitive way by developing charts and
graphs or easy interpretation.
We are yet to complete this step and hence, could not provide up exact
information. But we have observed that the current simulation design remains
inactive for 75% of the time.

3. Finding major flaws: Yet to be found out in the current design by applying
mathematical and statistical techniques to increase the efficiency and
effectiveness of the Warehouse. We would be experimenting with the
model through our intuitive sense to come-up with a unique and much
more productive one. Then we would finally compare the newly
developed models with the previous one and thence, would handover
the most feasible one as the recommendation to the industry.
 OBSERVATIONS & CONCLUSIONS
We observed that the current Warehouse Design remains inactive for almost
75% of the time. May be due to the supply of raw material issue. But we
believe it could also be due to the design of the Warehouse. The Pallets are
getting produced in excess and hence, some of the resources used in pallet
making could be redistributed in other areas of the Warehouse.

Conclusion
Although it is too early to arrive at any conclusion, but the following things
can be concluded with 100% surety:

 The resources distribution is not judicial in the present warehouse

model. The efficiency would increase significantly after reallocation of
resources.
 This business model, if applied may not produce much profit. There is
an urgent need to increase the supply (i.e., production through source)
which can solve almost all the problems.
 The current design uses two ASRS vehicles. This is not yet verified if it is
the best route to make the finished goods, but one thing is certain that
the second ASRS vehicle takes much more time than the first one to
complete the same amount of work. This problem can be solved by
increasing the speed at which both the vehicles operate.
 References
 FlexSim Basics Tutorial
 https://www.youtube.com/c/FlexSim
 https://www.dropbox.com/sh/h9vdsokngnhtb7c/AABEV_Lorz2brpIVxaAXaA48a/Automated%20Layout%20
Man ufacturing%20Simulation?dl=0&subfolder_nav_tracking=1