Configuration of an automated storage and retrieval system via simulation

The automation of warehouse operations has become essential for boosting efficiency and competitive edge in logistics management. Among the range of technologies available, Automated Storage and Retrieval Systems (AS/RS) have proven to be effective in enhancing inventory control and minimizing handling durations. This study presents the development of a simulation model using Tecnomatix Plant Simulation, a Discrete Event Simulation environment, to configure AS/RS in warehouse operations. The simulator is designed to support strategic, tactical, and operational decisions in the management of warehouse handling operations. It employs a Genetic Algorithm (GA) to efficiently manage sequences of dual cycles, where pairs of storage and retrieval tasks are combined to reduce overall handling time. The performance of this algorithm has been benchmarked against solutions obtained from optimally solving some test instances in simple cases. Computational experiments show that the genetic algorithm approaches optimal performance, with average gaps in handling time ranging from 1.00% for lower capacity utilization to 2.11% for higher loads. These results empirically demonstrate the validity of the approach, making a significant step forward in the optimization of warehouse operations through advanced AS/RS configurations.