Decision Support Systems

SIMULATION OF THE
SUPPLY OF FILLING LINES
António Santos | up202006883
Dinis Bichança | up20206980
Francisca Magalhães | up2006753
João Gonçalo Sobral | up202004258

2023-11-21
Agenda

Introduction

Methodology

Baseline Simulation Model

Alternative Scenarios

Conclusion

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Introduction
SuperBock’s Group

Largest player in the Portuguese beverage industry

Present in over 50 countries

PRODUCTS WAREHOUSE GOALS AND VISION

Beer; Leça do Balio, Portugal Hight quality standars;

Bottled water; On time deliveries;
Soft drinks; Minimizing Costs;
Ciders; Streamlined and agile processes.
...

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Introduction
Problem Context

Unloading bays Warehouse Filling Lines

Empty bottles and cans Small warehouse (JIT The pallets are moved to
arrive on trucks organized Production requirement); the filling line using forklifts
by pallets;
Forklifts are used to arrange allocated to the lines.
Four unloading bays; the pallets from the dock to
Pallet trucks are used to their positions in the
assist the operation. warehouse.

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Introduction
Problem Context

It is not possible to unload bottles or cans directly from the trucks on the docks.

The lines operate on a 7-day, 24-hour basis and stop for cleaning (8 hours a week) or SKU
changes.

Figure 1: Forklifts allocated to each filling line Figure 2: Container type filled in each line

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Introduction
Warehouse’s Layout

Recriation of
the warehouse
floor paln

Figure 3: Warehouse’s layout

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Introduction
KPI’s

To performe a logical analysis and evaluate the improvements of each alternative, the main key
performance indicators were identified...

Position Occupancy Rate

Loading Dock Occupancy

Occupancy of Handling Equipment

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Methodology
Data collection and Processing

The data provided of the unloading of pallets from trucks, and of the supply of pallets to
the lines was processed...

Calculation of the average hourly arrival rate of the trucks carrying bottles and the
interarrival time of the truck which carries cans (6 hours).

Calculation of the hourly supply rate of bottles to line 1, 2, 5 and 6 respectively, as

well as the hourly supply rate of cans to line 6.

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Baseline Simulation Model
Model Assumptions
There are four unloading docks, and in three of
them only bottles can be unloaded, whilst in
the fourth, only cans.
There are four trucks, one for each unloading
dock.
Trucks only bring bottles or cans at a time.
Each truck brings ten pallets to the warehouse
at a time.
At each dock, only one truck can unload pallets
at a time.
There are two separate storage spaces, each
with two levels: a larger one only for bottles
(the top one) and a smaller one only for cans
(the bottom one).
Only one forklift can unload the
trucks.
There four forklifts to the lines, according to
requirements .
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Baseline Simulation Model
Model Description

Distinct storage areas dedicated to bottles and cans

Agents
Unloading Dock
Rectangular nodes were used for the “forklift parking
Pallet area”, the four “receiving docks” and the four “filling
Truck lines”
ForkliftTruck
StorageBottles
Several resource pools, namely for each of the unloading
docks and for the forklifts of each line

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Baseline Simulation Model
Model Description

Figure 5: Flowchart of supplying pallets to lines

Figure 4: Flowchart of unloading and storage of bottles

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Improvement of Process
Alternative Scenario 1

Adding another line, only for cans, so that line 6 becomes only for bottles.

Figure 6: Flowchart of additional line

Less average occupation time of forklift per supply to line 6.

Changes in the layout and the cost of an additional line and the associated labour cost.

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Improvement of Process
Alternative Scenario 2

Adding a new forklift, so that each line has its own forklift, and line 5 has two.

No significant changes in the average occupation time of forklift per supply to each
line and in the average unloading time in each dock.

No changes to the layout but results in the cost of an additional forklift and the associated
labour cost

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Conclusion

Aternative scenario 1 is found to be the most beneficial

Combination of a complex real situation (Super Bock's operations) with

the limitations of Anylogic software

Iterative process and creation of alternative solutions

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Thank you!
António, Dinis, Francisca, Gonçalo

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