Case Study: DHL doubles warehouse throughput with AnyLogic simulation software

DHL cuts pick-and-pass activity 72% with AnyLogic

DHL, a leading global logistics company, faced significant inefficiencies in one of its large warehouse facilities. The challenges included dispersed stock-keeping units (SKUs), long travel distances for pickers, and frequent pick-and-pass operations, which limited order-picking efficiency and made it difficult to test improvements without disrupting daily operations. To address this, DHL turned to AnyLogic simulation software.

Using AnyLogic, DHL developed a detailed, cloud-based simulation model of their warehouse operations to test data-driven scenarios. This solution enabled the team to evaluate different slotting strategies and optimize workflows. The results were substantial: order-picking efficiency improved dramatically, pick-and-pass activity was reduced by 72%, and order turnaround time was cut in half from four hours to two, effectively doubling throughput.

DHL