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non-SKU warehousing.
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Design, simulate, and optimize non-SKU distribution —
orders and pallets, not SKUs and parcels.
IRVINE SIMULATION
THE NON-SKU WAREHOUSE DIGITAL TWIN
Purpose-built / Non-SKU distribution to businesses
DESIGN. SIMULATE. OPTIMIZE.
Find the constraint before it costs you a shift
Irvine Simulation is a discrete-event digital twin for
non-SKU distribution to businesses. Draw your building to the
pallet position, staff real shift schedules, release orders on the
monthly calendar — and watch every pallet move because a worker moved
it. No SKUs. No parcels. Your flow, simulated honestly.
Design
Lay out docks, staging lanes, racks, ticketing lines, and pick
paths on a 4-foot grid. Every square you paint is real, measured
capacity — down to which hub a staging position serves.
Simulate
A true discrete simulation. Unloaders walk the trailer, forklifts
drive routed aisles, selectors follow the serpentine pick path, and
orders release as current, future, or holdings.
Optimize
Building-level OPH, volume and idle-hours dashboard, live
bottleneck scoring, trailer aging, travel heatmaps, and seed-matched
A/B scenario comparison.
Built for
✓ Non-SKU pallet & carton flow
✓ Distribution to business customers
✓ Ticketing, releasing & monthly holdings
✓ Last-mile hub sortation & dedicated doors
Not built for
✕ SKU-level inventory systems
✕ E-commerce & parcel fulfillment
✕ Pick-and-pack retail operations
✕ Slotting or demand forecasting
If your building moves orders and pallets — not SKUs and parcels —
this is your simulator.
IRVINE SIMULATION
Your warehouses
Run a saved building, or open it in the builder.
No saved warehouses yet — build one!
Warehouse Builder
drag = rect fill · right-drag = erase · wheel = zoom · space/middle-drag = pan
Palette
Derived sim config
Conveyor Builder
drag = place a line (snaps 45° · hold shift = any angle) ·
ends snap to ports & lines · right-click = erase · Ctrl+Z undo ·
D = distances · R = rotate merge · C/T/G/E = tools ·
wheel = zoom · space/middle-drag = pan
Palette
System
How it flows
➕ Add Merge places The Merge — the X-to-1
sawtooth bed where every line in the building combines onto one
takeaway. Draw lines at any angle and end them on the numbered
port dots; ends snap to ports and to other
lines (mid-line joins become zipper merges). The merge controller
releases each input into a metered gap on the bed — set its logic
(zipper / slugs / deepest / longest-waiting) with the
⚙ tool (G), and rotate or drag the bed the
same way.
Conveyor Simulation
wheel = zoom · drag = pan
The Merge
0
cartons/min off the end
0%
takeaway occupancy
Total shipped0Cartons on system0Single merges—Merge inputs fed—Avg outbound gap—Avg dwell (throw→exit)—
Throw points
Settings
🤖 Auto-staff
Finds the smallest crew that still ships the building's
achievable volume (95% of a max-staff probe), using utilization-guided
search over headless simulated weeks — same seed, same layout.
Scenario compare
Both scenarios run headless for 7 simulated days —
same seed, same layout — and average the working days.
Order tracker
New warehouse
Custom store → hub table (optional — default: even ranges)
Grid scale: 1 cell = 4 ft × 4 ft = one pallet position.
Starter doors go on the left (inbound) and right (outbound) walls, but
the door tools can place them on any wall — right-click a door to remove it.
Irvine Simulation — drag the sliders, find the bottleneck.