Viastore Systems Case Study

Background

Viastore Systems is an international company specializing in automated material handling and a manufacturer of Unit load, Mini load, and Man aboard S/R machines, Automated Storage/Retrieval Systems (AS/RS), Automated Material Handling Control Systems and Supply Chain Execution software including Warehouse Management Systems (WMS).

Problem

Viastore Systems was bidding to build an automated unit load handling system for a new distribution center. Viastore Systems contracted Systemflow Simulations to simulate this system containing a three-zone AS/RS consisting of multiple aisles, a network of input/output conveyors, and shuttle cars that connect the main trunk conveyor with the AS/RS input/output conveyors.

Solution

Systemflow Simulations modeled the system using WMS data from an existing distribution center. The model simulated the system beginning with pallets entering the conveyor network and tracked through the shuttle cars and to the input points of the AS/RS, and again from the drop-off points where they exit the AS/RS and are placed on conveyors to exit the facility. Each aisle in the AS/RS consisted of several levels of elevation requiring precise modeling of the machine movements in three dimensions. Detailed control logic for one-bay and two-bay shuttle cars as well as the pallet conveyor itself was also implemented.

Viastore Systems also used this model to validate their mathematical calculations of the cycle times of the AS/RS for placing product into pick channels and into and out of storage locations. Systemflow Simulations chose the SLX simulation language for its flexibility to model detailed control logic and Proof Animation for its ability to produce smooth animations of complex systems.

Result

Working in close collaboration with the design engineers at Viastore Systems, Systemflow Simulations produced a high-fidelity simulation and a detailed animation of the proposed unit load handling system that inspired confidence that the design would meet the demands of the new distribution center. Viastore was awarded the contract.