Application: Factory Flow Simulation (EFS)
3DEXPERIENCE Version: 2023x

Business Need

I am developing a warehouse material flow simulation where four AGVs (trolleys) pick parts from multiple storage locations/aisles and deliver them to a common drop-off location.

The scenario may involve a large number of pickups (e.g., 150+ parts distributed across various pickup points), so I want to ensure that the model architecture is scalable and follows best practices.

Current Modeling Approach

I have attached the 3DXML model for reference.

The current model contains:

• 4 AGVs assigned to pick parts from different pickup locations.
• Multiple pickup zones connected through product flows.
• A common drop-off location.
• NC machines placed near pickup locations to enable Pull operation mode in zones.

I am encountering several issues and would appreciate feedback on whether my modeling approach is correct.

Issues Observed

1. AGVs Not Starting Simultaneously

At times, only one AGV is triggered. The remaining AGVs remain idle until the first AGV completes all of its pickup and delivery tasks.

Expected Behavior: All four AGVs should be able to operate concurrently when parts are available.

2. Pickup Sequence Not Followed

Some AGVs do not collect all required parts in the expected sequence. They occasionally skip pickup points and appear to select parts randomly.

Expected Behavior: AGVs should follow the defined product flow and complete all scheduled pickups.

3. Pull vs Push Mode Challenges

To use Pull mode, I added NC machines near each pickup location because without a resource, products are not generated in the zones and AGVs do not receive pickup requests.

When I switch all zones to Push mode, the model functions but simulation performance becomes significantly slower.

Questions:

• Is adding NC machines near pickup locations the correct approach?
• Is there a better method to generate pickup demand in Pull mode without creating dummy resources?
• Are there recommended practices for large-scale warehouse pickup scenarios?

4. Model Architecture Validation

I would like feedback on whether this overall approach is appropriate for a warehouse replenishment/material handling simulation involving:

• Multiple AGVs
• Multiple pickup locations
• One common destination
• Large pickup volumes (100–150+ parts)

Questions to the Community

1. What could cause only one AGV to be dispatched while others remain idle?
2. What settings typically affect AGV pickup sequencing and task allocation?
3. What is the recommended way to model demand generation in Pull mode for warehouse simulations?
4. When AGV drop parts to multiple places instead of 1 how that scenario to be modelled?
5. Is my overall modeling approach correct, or would you recommend a different architecture for scalability and performance?

Expected Outcome

I am looking for the most effective and scalable way to model a warehouse scenario where multiple AGVs simultaneously pick hundreds of parts from various aisles and deliver them to a common destination while maintaining realistic dispatching behavior and acceptable simulation performance.

Attachments

• 3DXML Model
• Video’s  showing
  • Only 1 AGV is working at a time.
  • Direct flow from In zone and keeping mode Pull is not triggering AGV pull.

  • Changing in zone to pull then adding a NC machine before load is triggering simulation well.