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The warehouse consists of a front rack zone for pallet storage and gravity racks for fast picking in the conveyor picking zone. The resources consist of forklifts, flow racks, and conveyor picking operators, whose capacities can be dynamically changed at runtime.
The process works as follows: received pallets are stored in the storage area, wholesale orders are picked and put away to the shipping area. Gravity racks are replenished by splitting full pallets into individual boxes and loading them onto the racks. Totes for sales orders are dispensed on the conveyor and diverted to picking areas, where the required products are picked. Utilization statistics for zones, forklifts and operators are measured at runtime.
It was difficult for the warehouse owner to decide on an investment in a conveyor system because he was not sure how the replenishment would work. A visual model and simulation helped make the right decision.