Featured project
Warehouse Sequence Optimization
Medline Industries · April 2024
Managed and led the implementation of discrete-event simulation through FlexSim to optimize warehouse processes.
This work centered on modeling real warehouse flows so we could test sequencing and staffing changes before rolling them out on the floor. The simulation made trade-offs visible—where queues formed, how operator paths compounded delay, and which changes actually moved the metrics leadership cared about.
Key results
- 17% improvement in operator efficiency
- 26% reduction in overtime hours
Technologies & focus
Case study
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FlexSim & simulation
3D layout and flow logic built in FlexSim to mirror production behavior.
Flowchart of the logic built in FlexSim to mirror production behavior, along with statistics showing the impact of a sequencing change on operator efficiency and overtime hours.
Baseline pick path: snake-like routing through the aisles (before optimization).
Improved pick path: zig-zag routing that reduced travel and supported higher operator efficiency.