Warehouse Simulation Consultant

Tata Consultancy Services; Bengaluru; On-site; INR 1,500,000 - 3,000,000; Full time

Job summary

Tata Consultancy Services in Bengaluru is seeking a senior professional to develop and deploy warehouse/distribution center simulation models. You will focus on throughput improvement, capacity validation, labor optimization, and layout decisions to support warehouse digital twin initiatives.

Responsibilities include leading workshops, building baseline and future-state DES models, and delivering KPI dashboards and reports for end users.

Qualifications

• Experience in building warehouse and distribution center simulation models.
• Validation of throughput, labor productivity and dock capacity.
• Knowledge of warehouse layout design, slotting and dispatch planning.

Responsibilities

• Conduct requirement gathering workshops with warehouse, logistics, engineering, operations and automation teams
• Study current warehouse operations, material flows, order profiles, shift patterns and equipment usage to define simulation scope
• Build baseline and future-state discrete event simulation models for warehouses and distribution centers
• Model flows such as inbound pallets, finished goods storage, route loading, staging lanes, trailer loading and dock scheduling
• Define and execute what-if scenarios for layout changes, automation options, capacity expansion and labor planning
• Analyze simulation outputs and prepare recommendations on bottleneck elimination, throughput improvement and resource optimization
• Coordinate model reviews, validation sessions and stakeholder sign-offs with client teams and document results

Skills

Warehouse simulation

Discrete event

Throughput optimization

Labor optimization

Capacity validation

Layout design

What‑if analysis

KPI reporting

Job description

• 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