Introduction
Whether your automated system is brand new or aging, the question is the same: Is it ready for peak season and performing at the highest level? Many organizations face challenges in conducting thorough live testing due to the significant time and resources required—especially when new automation is installed within an existing operation. And, when installing an automated system within a new facility, it’s critical to allocate sufficient time for comprehensive testing. Proper preparation ensures smooth operations not only during startup but also throughout regular volumes and seasonal surges. While automation delivers significant efficiencies when functioning as expected, any breakdowns can lead to costly and disruptive manual workarounds.
Testing Automated Systems
Automated systems range from basic multi-level pick modules with sorters to advanced AS/RS systems, shuttles, AMRs, and more. Regardless of technology, each system has multiple potential failure points that must be tested to ensure reliable performance during both regular and peak periods. Key areas to evaluate include:
- Control software integration and functionality
- Equipment dimensions and weight handling
- Throughput rates and speed
- Product and equipment alignment
- Inventory dimensions and weight
- Travel paths and routes
- System reporting and alerts
Traditional Live Testing
Live testing remains the most direct method for confirming system readiness, particularly in new facilities. While it may temporarily impact daily operations, it provides critical insights into real-world performance. A successful live testing strategy typically involves:
- Securing necessary inventory (e.g., cases, pallets)
- Loading and processing inventory through the system
- Allocating staff to support testing activities
- Coordinating with other operational or installation schedules
- Identifying and documenting issues for resolution
Simulation Modeling
If live testing isn’t feasible due to time and/or resource constraints, consider building a simulation model. This analytical approach allows you to evaluate system performance and identify areas for improvement without disrupting operations. Simulation modeling is especially valuable during the detailed engineering design phase to validate concepts and optimize performance. With this approach to testing, you avoid the need to manually handle inventory, use labor resources, and impact the day-to-day operations.
Simulation models can be developed for a focused area and provide results within a month or take twelve (12+) weeks to build for a large/complex system and data is not available. Although building a full simulation model can take months, interim results can be assessed section by section to guide adjustments. The basic simulation requirements include the following:
- Collecting and validating data files (inventory, orders, etc.)
- Data model processing and analysis
- Defining / validating operational system descriptions
- Building physical simulation model / logic development
- Running scenarios and reporting findings
- Testing resolutions and documenting recommendations
Developing a Testing Strategy
Start by defining your peak season expectations—inventory levels, order volumes, SKU mix, and order profiles. Then assess your available resources and timeline to determine whether you can pursue live testing, simulation modeling, or both.
Remember, testing is only part of the process. If issues arise, you’ll need time to develop, test, and implement adjustments such as:
- Modifying order wave timing
- Revising shift schedules or staffing plans
- Tweaking control software
- Making equipment changes
Conclusion
Identifying and resolving issues before peak season and on-going is critical to maintain performance and avoiding disruptions. Simulation models can also serve as tool to monitor system health and pinpoint areas for continuous improvement.
If you’re looking to develop a testing strategy, conduct live testing, and/or build a simulation model, reach out to St. Onge Company. We’re here to help you succeed—during peak season and beyond.
—Norm Saenz, St. Onge Company
