Simulate warehouse operations and optimize storage utilization. Part of the DevTools Surf developer suite. Browse more tools in the Business & Corporate collection.
Use Cases
Simulate pick path optimization for a warehouse layout before physical rearrangement.
Model storage slot assignment based on item velocity and physical dimensions.
Test receiving workflow scenarios to identify bottlenecks in inbound processing.
Evaluate the impact of zone picking vs. wave picking on order fulfillment throughput.
Tips
Implement ABC analysis before designing storage layout: A items (fast-moving, 80% of volume) should be closest to packing stations, C items (slow-moving) in the deepest storage.
Design pick paths to minimize travel distance — a U-shaped or serpentine path is typically more efficient than random picks from the shortest distance for each individual item.
Track receiving accuracy separately from pick accuracy — receiving errors propagate through the entire fulfillment chain and are harder to detect late.
Fun Facts
Amazon's fulfillment center in Etna, Ohio is one of the largest in the US at 3.8 million square feet — roughly 65 football fields. It uses over 3,000 robots (Amazon Robotics Kiva systems) alongside human workers.
The Kiva Systems robotics company was acquired by Amazon in 2012 for $775 million and renamed Amazon Robotics — the acquisition gave Amazon a significant competitive advantage in warehouse automation.
Warehouse Management Systems (WMS) as commercial software emerged in the early 1990s. The global WMS market was valued at $3.1 billion in 2022 and is projected to reach $6.2 billion by 2028.
FAQ
What is the difference between zone picking and wave picking?
Zone picking assigns pickers to a geographic zone — they only pick items in their zone, and orders are consolidated at a merge point. Wave picking releases groups of orders simultaneously to smooth workload and optimize travel.
What is the ABC analysis in warehouse management?
A items: fast-moving (top 20% of SKUs accounting for 80% of transactions) — store in prime locations near packing. B items: moderate velocity — mid-level storage. C items: slow-moving — deepest storage. Reduces average travel distance per pick significantly.
