Simulation-Based PerformanceEvaluation of Alternative WarehouseAutomation Concepts : A Comparative Evaluation of AS/RS and AGV-Systems in an Industrial Box Warehouse Case

Sammanfattning

Early-stage warehouse design requires selecting between alternative automation concepts under conditions of uncertainty, where decisions have long-term implications for system performance, flexibility, and scalability. In this context, evaluating and comparing automation solutions prior to implementation is essential for informed decision-making. This study addresses this challenge by first identifying and structuring relevant performance measures for warehouse automation evaluation, and subsequently applying these measures in a comparative analysis of Automated Storage and Retrieval Systems (AS/RS) and Automated Guided Vehicle (AGV) systems. The study is conducted as a quantitative case study at Scania Oskarshamn, focusing on a box warehouse in an industrial setting. Discrete-event simulation models were developed in Tecnomatix Plant Simulation to represent both automation concepts under the same overall layout and input conditions. The systems were assessed across multiple experimental scenarios using selected performance measures, including throughput capacity, makespan, dwell time, and system performance under failure conditions. The results show that the AS/RS system provides higher inherent throughput capacity and more stable processing times, accommodating both 50% and 100% increases in load within its existing configuration, although its performance is bounded by crane handling capacity. The AGV system requires additional vehicles to reach comparable throughput levels and exhibits decreasing efficiency as fleet size increases due to vehicle interaction. At the same time, it demonstrates greater operational robustness under failure conditions and maintains full accessibility to storage locations. In terms of makespan, AS/RS shows shorter and more consistent processing times, whereas AGV exhibits longer and more variable makespan performance, reflecting greater sensitivity to operational parameters. The analysis further shows that the systems are constrained by different types of bottlenecks, where AGV performance is limited by shared transport resources, while AS/RS is constrained by fixed handling capacity. The findings highlight a trade-off between efficiency and flexibility. AS/RS is better suited for stable, high-demand environments requiring consistent performance, whereas AGV offers advantages in adaptability under varying operating conditions. By combining structured evaluation measures with simulation-based analysis, the study provides support for decision-making in early warehouse design.