Order picking using process flow not working

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Vincent Leong asked Dec 4, '24 Vincent Leong commented Dec 13, '24

Order picking using process flow not working

warehouse-demo-model_layout_yangbum (3).fsmHi all, my simulation is a warehouse of my company, I'm currently facing 2 issues

1. My operators stop at 3pm when i run my simulation

2. Outbound order picking order using process flow not working. I want the orders to be picked have a same number of quantity and same type from racks. ( I want the order picker to load items from racks to the QC label area)

current process flow

I'm doing a current state of the warehouse to do improvements. the Future state will be using robot hands and movable racks. If you guys have any models for reference please send thanks.

Software Version:

FlexSim 24.2.1

process flow warehouse orderpicking simulations

1733301867458.png (12.0 KiB)

warehouse-demo-model-layout-yangbum-3.fsm (2.2 MiB)

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Answer 1 · 2024-12-04T10:46:44Z

jc answered Dec 4, '24 Vincent Leong commented Dec 13, '24

Hello, Vincent:
The issue with the outbound is that the tags are inverted:

the tokens that go through find object don't have any label named "Type", they have a label product, so that is what you have to put in the $1. And the boxes in the storage dont have a label product, they have the label Type, so that is what you need to write in the query, as you can see in the image.

Besides, I have seen that here are several products that cannot be found because they are being created in the pallets.

These objects will never be found by the "find objects" in the storage system. You need to find a slot for objects 1-8 like you do it for objects 8-19:
Otherwise,tokens will be stuck in find object activity in the outbound and eventually tokens will be also stuck in find slot n the inbound because there wont be free room for new objects.

I hope this helps you.

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1733308966146.png (303.5 KiB)

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Vincent Leong commented · Dec 05, 2024 at 10:12 AM

Hi jc, about the process flow for outbound,it appear that the token is still stuck at find slot after I change the taggings. And about the "find item" can you help suggest where in the process flow should it put it in, thanks

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jc Vincent Leong commented · Dec 05, 2024 at 10:31 AM

I didn't fully understand your answer. In the outbound there is no "find slot", but find item, right?
If what you mean is that the token are stuck in the "find item" in the outbound it is probably due to the fact that the items type 1 to 8 are created in pallets. Therefore they cannot be found by that "find item" activity.
I also don't understand what you mean by putting the "find item" in the process flow? If you refer to the last part of my answer, what I suggest you to do is to change the Initial source process flow for the objects of type 1-8 and not create them on pallets but create them like you create objects 8-19, by creating them frist and then finding a slot for them and then move them to the racks like you do with the objects 8-19.
I don't know if the pallets need to be there and if the objects need to be on the pallets, but the easiest solution would be that.
If this is not what you meant, maybe you can send me the updated model.
Let me know if I can help you in anything else.

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Vincent Leong jc commented · Dec 05, 2024 at 02:37 PM

Oh I kinda understand what you meant about the token being stuck at find item because they cannot find the boxes on pallet. However to illustrate the warehouse in my project the boxes are create in pallets like in real life .

1. Is it possible to use possible to create boxes on pallet and the operator can pick from them.

2. Is it possible for the operator to pick the whole pallet using find item as I want it to go through an unpacking and packing process by using separator and combiner ?

3. How do I make find item to find just objects 8-19?

Thanks for answering my doubts.

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