Warehouse Operations Improvement Using Simulation Modelling: Study of a Plumbing Equipment Manufacturer

This research is to improve warehouse processes with a case study model of a manufacturer and distributor of plumbing equipment. with the purpose of presenting improvement guidelines. By comparing the results of improving warehouse processes to be more efficient. Reduced cycle time, increased material handling equipment utilization and fewer operators. From the case study, the company found that warehouses currently operate in wave chains with long cycle times (1.88 minutes per pallet) in picking activities. Utilities for handling equipment were low (28.97%) in Put-away activities with many operators (8 people per day), thus improving the warehouse process. Therefore, it starts with collecting time data. analyze the data and model the current situation. Validate and apply the model to the case study company to determine the appropriate number of handling equipment and the number of operators. The number of stackers increased from 1 to 3, the number of hand lifts and the number of operators remained the same. This resulted in a 34.48% reduction in cycle time in picking activities and a 38.08% increase in material handling equipment utilization in put-away activities, with no more than 66.45% of operator workload.