Abstract
The rapid advancement of warehouse automation has increased the need for intelligent intralogistics solutions that enhance material handling efficiency and optimize space utilization. This research presents a simulation-based methodology that integrates Autonomous Mobile Robots (AMRs) with container loading optimization in a unified decision-support framework that dynamically synchronizes AMR routing with optimized truckload configurations, a feature not commonly addressed jointly in existing literature to improve warehouse operations. By leveraging a hybrid approach combining discrete event and agent-based simulation in FlexSim, the study evaluates the impact of AMR fleet size, routing strategies, and truckload configurations on overall logistics performance. A proof-of-concept industrial case study illustrates how different scenarios influence key performance metrics, such as total operation time and resource utilization. The findings demonstrate that synchronized AMR deployment and optimized container loading strategies contribute to increased throughput, reduced handling time, and enhanced logistics unit utilization. This work provides a framework for dynamic logistics planning, offering valuable insights for companies seeking to enhance warehouse efficiency and sustainability through simulation-driven decision support. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.

Abstract
The adoption of Autonomous Mobile Robots (AMRs) has emerged as a promising solution to enhance efficiency and reduce operational costs for industrial companies. Given the significant cost of AMRs, it is crucial to determine the optimal number and characteristics before making significant investments. This study proposes a decision-support framework based on simulation to assess the impact of integrating AMR robots in a complex distribution center. Additionally, this framework aids decision-makers in determining the optimal fleet size of AMR robots and corresponding charging stations. A simulation model was developed using data from a leading retail company, focusing on pallet movement within the facility, comparing scenarios combining AMRs with other intralogistics implementations. This methodology incorporates uncertainty, variability (statistical distributions to create transportation orders, acceleration, demand and offer fluctuations) and implements fleet management, transportation capacity, demand matching, and resource utilization according to real case scenarios. The proposed model replicates accurate robot coordination and actual deployment environments, ensuring that the tested scenarios approximate the real-world conditions as much as possible. Preliminary findings show results supporting the decision-making for a fleet size to meet weekly production targets, optimize robot utilization, and coordinate charging instances to prevent production stops. Conclusions suggest that the proposed simulation approach is an effective tool for planning and implementing logistics solutions, enabling users to make informed decisions before investing. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.

Abstract
Industry 4.0 is transforming manufacturing environments, with robotics being a key technology that enhances various capabilities. The flexibility of Autonomous Mobile Robots has led to the rise of multi-robot systems in industrial settings. Considering the high cost of these robots, it is essential to determine the best fit of number and type before making any major investments. Simulation and modeling are valuable decision-support tools, allowing the simulation of different setups to address robot fleet sizing issues. This paper introduces a decision-support framework that combines a fleet manager software stack with the FlexSim simulator, helping decision-makers determine the most suitable mobile robots fleet size tailored to their needs. Unlike previous approaches, the developed solution integrates the same real robot coordination software in both simulation and actual deployment, ensuring that tested scenarios accurately reflect real-world conditions. A case study was conducted to evaluate the framework, involving multiple tasks of loading and unloading materials within a warehouse. Five different scenarios with varying fleet sizes were simulated, and their performances assessed. The analysis concluded that, for the case study under consideration, a fleet of three robots was the most suitable, considering relevant key performance indicators. The results confirmed that the developed solution is an effective alternative for addressing the problem and represents a novel technology with no prior state-of-the-art equivalents.

Abstract
Warehouses and distribution centres play a key role in any Supply Chain, particularly in the retail sector, where a network of stores needs to be replenished in a highly dynamic and increasingly uncertain context. In this regard, companies need to improve their intralogistics systems daily to ensure long-term competitiveness and sustainable growth. This is especially true in picking-by-line systems where many time-consuming and manual tasks are usually involved. This study introduces a new decision support tool based on simulation methods to aid the decision-making process in a picking-by-Line system, aimed to improve the overall picking operations efficiency, through human-centric perspective. A Discrete-Event-Simulation model is proposed to assess a set of parameters under several scenarios, driving a more informed decision-making process towards cost-effective strategies. The proposed approach was validated through an empirical case study showing its effectiveness in assisting operational planning decisions related to capacity and resource allocation. The system demonstrates promising versatility for application across varied warehouse environments. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.

Abstract
In the dynamic realm of nowadays manufacturing, integrating digital technologies has become paramount for enhancing operational efficiency and decision-making processes. This article presents a novel system architecture that integrates a Simulation-based Digital Twin (DT) with emerging trends in manufacturing to enhance decision-making, accompanied by a detailed technical approach encompassing protocols and technologies for each component. The DT leverages advanced simulation techniques to model, monitor, and optimize production processes in real time, facilitating both strategic and operational decision-making. Complementing the DT, trending technologies such as artificial intelligence, additive manufacturing, collaborative robots, autonomous vehicles, and connectivity advancements are strategically integrated to enhance operational efficiency and facilitate the adoption of the Manufacturing as a Service (MaaS) paradigm. A case study within a MaaS supplier context, deployed in an industrial laboratory with advanced robotic systems, demonstrates the practical application of optimizing dynamic job-shop configurations using Simulation-based DT, showcasing strategies to improve operational efficiency and resource utilization. The results of the industrial experiment were highly encouraging, underscoring the potential for extension to more intricate industrial systems, with particular emphasis on incorporating sustainability and remanufacturing principles.