Using simulation to optimize a horizontal carousel storage system

Carousel storage systems are often used to increase storage density, throughput and efficiency while reducing inventory and man hours. The Hewlett-Packard company has developed a computer simulation model in an effort to fully optimize its horizontal carousel storage system. HP assembles and packages a wide range of inkjet printers at its Vancouver, Washington (VCD) manufacturing facility. The simulation project was initiated to provide an accurate prediction of system performance based on a given set of input parameters. Case study scenarios can test parameters such as different storage algorithms, selection criteria, carousel speeds, rotation direction, production rates, and more. Changes to the control logic can be analyzed without implementing them in the real control system. The effects of new product types and production plans can also be analyzed prior to production change-overs. The simulation model provides an accurate statistical report from which each scenario can be evaluated. The paper presents a flexible, carousel simulation model built using a general purpose simulation language. This data driven model serves as a template which can easily test configurations and options used in the real system. The advantages of this carousel simulation model as an analysis tool and the benefits that have come to HP as a result of simulation analysis are presented.