Design, Planning, Simulation and Optimization

Digitalized holistic planning process

Holistic consideration of the entire logistics planning process from location search to operational use - all in one tool

Automatic layout generation as a quick benchmark for space requirements and labor costs

Detailed simulation / analysis: identification of potential improvements, support for strategic decisions

Integrated process analysis with direct transfer of required parameters into a simulation model

Practical evaluation of automation and mechanization possibilities

Improvement of results and labor savings in tendering and calculation of logistics services

Consistent database allows efficient data collection, verification, consolidation and handling in one tool due to its modern architecture

Extensive statistics for an in-depth analysis of input data and results, visualization of data and results in 2D and 3D, sustainable setup by extrapolation and scenario calculation

DIGITAL TWIN FOR WAREHOUSES AND DISTRIBUTION CENTERS

Combination of a 3D model with current information from live data (such as tracking) as well as data from other systems such as dimensions, throughput, or inventory of individual products or materials
Simulation of material flow, staff deployment, and use of forklift trucks
Identification and elimination of unproductive processes
Integration of video process studies
Testing and evaluation of the impact of layout changes, new equipment, and new processes
Dynamic optimization of warehouse assignment, staff, and material deployment

W2MO provides the possibility to create a digital twin for the design, optimization, and operation of warehouses and distribution centers. A 3D model is combined with business data from the warehouse management or ERP system, such as master, inventory, and consumption data, and can additionally be enriched with live data (for example, from tracking). Video process studies with a direct transfer of the required parameters into the digital twin additionally increase the accuracy. This provides the basis for a detailed analysis of planning alternatives and the identification or elimination of unproductive processes and procedures. With a digital twin, the boundaries between planning, continuous improvement, and dynamic optimization of operational processes become blurred.

Design by Efficiency

Consistent evaluation and optimization of processes and structures during the restructuring or planning of a new location
Holistic modeling in warehouse and production logistics
Determining decisions and investments with the help of scenario comparisons
Collecting all data and information in one tool without media discontinuity

Future workload in logistics is calculated with high accuracy during the W2MO layout planning based on standard times. That is why costs and benefits of each layout or process change can be seen and evaluated immediately. This includes the full range of manual to fully automated systems in warehouse and production logistics. The workload for each step is chronologically evaluated, from inbound through stand-by zones or supermarkets to further handling of picked or manufactured products. An extensive set of intelligent algorithms is available for the design of logistics structures. The use of automation technology can thus not only be compared with simple methods of storage space allocation and tour building but can also be evaluated in detail; for example, how the walking efforts of employees differ using goods-to-man systems compared to the use of intelligent algorithms.

STANDARD TIMES & VIDEO PROCESS STUDIES

Easy recording, analysis, documentation, and optimization of all kinds of processes in production and logistics
Detailed calculation of the workload, split into separate elements, processes, or granular activities
Recording / analyzing of both speeds and times
Privacy protection through automated head blurring
Direct transfer of evaluated parameters to the digital twin for future computations
Performance rating of employees: setting target times, e.g. for a complete picking process including packing and labeling, and comparing with as-is times

W2MO supports process studies with easy and simple recording, analysis, and documentation of times and speeds in all logistic processes. The unique combination of video recording and a digital twin allows you to evaluate not only times but also speeds. This helps to compute realistic times depending on the chosen driving path as well as the start and end points. No average times are used. On that basis, processes can be optimized and extremely time-consuming steps can be eliminated. Privacy protection is also considered. With integrated head blurring people can be anonymized in video recordings. W2MO offers the possibility to use the required parameters for setting targets for the employees; e.g., for a single pick including packaging and labelling.

AUTOMATIC LAYOUT GENERATION (LAYOUT DESIGN OPTIMIZER)

Digital Twin: Layout creation with just a few clicks
Planning of the ideal location capacity and warehouse space
Different levels of detail depending on the data basis
Calculation of costs for equipment, staff, and inventory
Result: complete simulation model for further studies

The Layout Design Optimizer (LDO) enables the automatic creation of optimized warehouse layouts with just a few clicks. The goal is to automate, optimize, and accelerate the process of layout creation. Depending on the data availability, very detailed figures on product and orders can be processed or alternatively calculated based on a few statistical parameters. The result is a complete 3D simulation model that includes the required space, suitable racking structure, and necessary equipment. A bill of material for the required inventory can be deduced in addition to the expected labor costs. This fast and uncomplicated model is a first benchmark and forms the basis for further detailed planning.

Warehouse Capacity Optimization

With the warehouse capacity optimization in a first step the optimal sizes of storage places are calculated based on product properties, stock data and demand behavior. In a second step those optimally sized storage places are placed in the warehouse efficiently to maximize the effective storage capacity. Apart from this approach based on the placement of single storage places (e.g. ideally for pallet storage) the innovative algorithms in W2MO also might restructure warehouses optimally with dynamic used bulk areas to increase the fill level of the used areas significantly (e.g. in warehouses with a heterogeneous product portfolio).

Strategic calculation of optimal bulk area sizes
Optimization based on multiple stock snapshots and consideration of storage stratgies
Flexible definition of constraints and fast analysis of the effects
Increasing of the effective storage usage and the fill level of used areas by up to 20%
Increasing of the operative efficiency due to improved storage management.

TENDERING AND CALCULATION OF LOGISTICS SERVICES

Easy and extensive preparation of data and quantity structures
Digital process documentation and description
Transparent calculation basis for all products and processes
Structured evaluation of growth and risks
Understandable solution visualization for an optimal offer presentation

W2MO can provide digital support during the tendering of logistics services on both sides of the negotiation table. Using time components, providers can quantify logistics costs more accurately and reliably. The customer can check the effects of various business developments with the help of data extrapolation and scenario management. In contrast to common calculation tools and excel sheets, these W2MO options can be quickly created and evaluated. Tendering participants can efficiently calculate the planning options, graphically process the results, and present them in diagrams and understandable 3D models. Created models can be used for operational optimization and can be transferred for new projects.

DATA COLLECTION AND VALIDATION

Use of standard data templates for import and export
Integration with SAP or other ERP / warehouse management systems
Automatic verification of data consistency and correction of data errors
Creation of a unified database for simulation and optimization projects

Product master data, movement data, customer orders, inventory – only a few business areas have the same data information level as the logistics sector. Therefore, structured handling of big data is key to optimize the layout and processes, to recognize long-term trends and to evaluate the alternatives. W2MO offers a variety of configurable interfaces for each use case. Data for planning tasks can be prepared in Excel and can be uploaded as a .csv file. Alternatively, data from WMS, ERP, or TM systems can be transferred automatically each day. The SAP connector provides a standard interface to all SAP systems. W2MO offers algorithmic support to validate used data and allows automatic correction of data errors. Model errors, data gaps and contradictions are avoided and repaired directly. At the same time W2MO has a consistent database for simulation and optimization projects.

DATA GENERATION AND EXTRAPOLATION

Generation of product and order data with the help of statistical key figures
Creation of future scenarios based on historical data
Maintenance or targeted modification of order structure for planning scenarios
Easy closing of data gaps

Planning or optimizing of a logistics process is always future-oriented. Exact data on product and order structures are only available from the past. That is why W2MO offers the possibility to create product and order data using statistical distributions. Moreover, a valid simulation model can be created with a very limited amount of data. Sophisticated extrapolation algorithms help to generate goal-oriented foresighted order structures. The result is based on historical data and accurately reflects the expected business development. This methodology is implemented to fill any existing data gaps when required.

DATA ANALYSIS

Diverse analysis and evaluation possibilities
Graphical representation in 2D and 3D
Heatmaps for data visualization
Possibility to export the results for further processing

W2MO provides a variety of analysis and evaluation possibilities for the created database and achieved results. The layout information in 2D and 3D helps to create heat maps for access times, picking amounts and labor costs. Such visualizations often enable identifying optimization potentials and transparently showing inefficiencies in current processes.

SCENARIO COMPARISON

Scenario-manager for campaign-dependent data management
Easy comparison of different scenarios
Evaluation of various growth options
Comparative analysis of results in detailed reports

Growth scenarios, market entries, segmentations, developments in the product portfolio – with the extrapolation functions of W2MO, you can always create a realistic and structured database for your scenarios. The simulation in W2MO enables evaluation of planning scenarios based on real costs and capacity requirements. Different layout scenarios and different warehouse techniques, picking strategies and warehouse assignment strategies can be quickly and easily modeled and evaluated. The evaluation of scenarios based on simulation allows you to compare the resulting logistics parameters and performance indicators. Not only static parameters are analyzed but also dynamic effects such as bottlenecks and load peaks are evaluated.