Brewer Distribution Center Modeling

Automotive distribution operations depend on precise coordination between automated storage and retrieval systems (ASRS) and conveyor infrastructure. Before commissioning a new distribution center, Brewer faced the challenge of verifying that its planned ASRS and integrated conveyor system would perform reliably under real-world demand variability. Without pre-deployment validation, unforeseen bottlenecks in pallet flow — particularly during peak intake and outbound surges — could cause costly downtime, missed shipments, and expensive post-installation redesigns. The complexity of the multi-level layout made manual analysis insufficient to predict system behavior accurately.

Rockwell Automation developed a digital twin of the distribution center to simulate the facility's full operational logic before physical installation. The model captured the complete pallet flow: from the main scanner level, pallets travel in pairs via two elevators to the two levels above, feeding four pick-up points for narrow-aisle cranes. Each aisle contains two pickup and two dropdown stations placed asymmetrically across the levels, with each aisle split into two sections — each served by a dedicated narrow-aisle crane with its own loading and unloading stations. The crane sequencing logic, including the vertical repositioning required after unloading each pallet pair, was fully animated within the simulation. Individual animated statistics were overlaid on the layout to allow engineers to monitor throughput and utilization in real time during testing.

The simulation confirmed that the designed system was highly robust, capable of absorbing the anticipated peaks and troughs in pallet input and output without service disruption. Critically, the digital twin surfaced unexpected bottlenecks that had not been identified through conventional design review — findings that were subsequently verified by the system's original designers. Feasible design modifications were tested within the simulation environment and incorporated into the final physical build before construction, avoiding costly change orders. The validation process gave stakeholders confidence in system performance prior to capital commitment.

• Simulate before you build: Digital twin validation of ASRS and conveyor systems can surface hidden bottlenecks that static design reviews miss, reducing post-installation rework costs.
• Designer verification adds credibility: Having the system's original engineers confirm simulation-identified issues strengthens the case for design changes and accelerates approval.
• Model the full flow, not just segments: Accurate results required capturing the entire pallet journey — elevators, cranes, asymmetric station placement, and vertical crane repositioning — not isolated subsystems.
• Peak-and-trough testing is essential: Validating performance under demand variability, not just average throughput, is the true measure of distribution system resilience in automotive logistics.