SOLVING THE BOTTLENECK PROBLEM IN A WAREHOUSE USING SIMULATIONS

Abstract

The uneven workload distribution and working time utilisation create a bottleneck, leading to inefficient utilisation of capacity and increased costs. A bottleneck is a limiting and risk factor for any business entity. In the case of a distribution warehouse, the bottleneck limits its ability to meet the requirements for sending an order within the required time limit. Delays at any phase of a distribution process may result in non-compliance with customer requirements. In solving capacity problems and bottlenecks elimination, computer simulations and optimisation are often used. The article presents a basic simulation analysis of workload distribution and work times, useful for logistics companies, thus for the area of human and financial resources. In the article, the use of simulations in the ExtendSim9 program to eliminate the bottleneck is discussed. The bottleneck is solved by experiments on a simulation model when optimal workers assignment to individual workplaces of the warehouse is sought. The two final proposals for workers allocation, with the current and increased number of workers, are compared in workforce utilisation and system stability. The simulation method allows verification of the proposals' impacts in advance and practically with no financial costs.