Warehouse Simulation Consultant

Required Skills:

• Strong hands-on experience in building warehouse and distribution center simulation models covering inbound receiving, put-away, storage, replenishment, picking, palletizing, staging, loading and dispatch operations
• Experience in CPG / FMCG warehouse operations, preferably beverage, snacks or high-volume distribution environments with pallet, case and route-to-market flows
• Ability to model conveyors, forklifts, pallet movement, operator travel paths, dock doors, storage zones, AS/RS, sortation, accumulation buffers and material handling equipment
• Experience in validating warehouse throughput, labor productivity, equipment utilization, bottlenecks, inventory levels, dock capacity, staging capacity and service-level performance
• Strong capability in what-if scenario analysis for demand spikes, SKU mix variation, shift patterns, labor planning, trailer schedules, layout alternatives and automation investments
• Good understanding of warehouse layout design, slotting logic, storage policies, replenishment rules, order batching, picking strategies and dispatch planning
• Knowledge of simulation programming, data interfaces, dashboards and KPI reporting for warehouse digital twin / discrete event simulation use cases

7+ years of experience in developing and deploying warehouse, distribution center or logistics simulation models for throughput improvement, capacity validation, labor optimization and warehouse layout decision support

Responsibilities:

• Conduct requirement gathering workshops with warehouse, logistics, engineering, operations and automation teams
• Study current warehouse operations, material flows, order profiles, shift patterns, equipment usage and operational constraints to define simulation scope and assumptions
• Build baseline and future-state discrete event simulation models for warehouses, distribution centers and connected manufacturing-to-warehouse flows
• Model specific flows such as inbound pallets, finished goods storage, route loading, staging lanes, trailer loading, dock scheduling, pallet movements and operator / forklift travel paths
• Define and execute what-if scenarios for layout changes, automation options, capacity expansion, labor planning, SKU mix changes, demand peaks and service-level improvements
• Analyze simulation outputs and prepare recommendations on bottleneck elimination, throughput improvement, resource optimization, storage utilization and dock / staging capacity
• Coordinate model reviews, validation sessions, issue resolution and stakeholder sign-offs with client business and technical teams
• Prepare simulation reports, KPI dashboards, scenario comparison summaries, user guides and training material for end users