Using discrete-event simulation to enable implementation of picking and palletizing robots: A case study

Abstract: Aim: The study aims to develop a DES model to evaluate the impacts of implementing packaging and palletizing robotics in the goods-receipts process. Research questions: RQ1: “What are the requirements when developing a Discrete Event Simulation (DES) model of the goods receipt process in the internal logistics section of a manufacturing company?”, RQ2: “What is the impact of implementing a new layout with industrial palletizer robotics in manufacturing companies' internal logistics - specifically the goods receipt process in terms of robot Overall Equipment Effectiveness (OEE), throughput, and WIP?” and, RQ3: “What considerations should companies take into account when implementing industrial palletizer robotics in their internal logistics, in terms of process flow?” Methodology: This study applied an inductive approach, letting the empirical findings guide the themes explored in the theoretical framework while having a constant interplay between empirical data collection and the construction of the simulation model. Empirical data collection was collected via observation, time study, and documentation. Literature was collected via Scopus and restricted to peer-reviewed articles and book chapters. The simulation model building followed the steps presented by Banks (2005). Based on the model building and simulation model results, conclusions could be made. Conclusion: The study concluded and presented nine requirements to develop a DES model for the goods-receipt process in manufacturing companies' internal logistics. The impact of robot OEE was determined to be low, 24-27%, WIP increased, and throughput increased with the implementation of a new layout with an industrial palletizer robot. Lastly, to answer RQ3, the study concluded and presented six considerations for companies to take into account when evaluating the implementation of an industrial palletizer robot