A new facility is a $100M+ bet, and the only way to validate it is a simulation model that takes weeks to hand-build and quietly drifts from reality. Flow Cast Tech builds the model for you in seconds, finds the constraint a spreadsheet can't see, and is calibrated against how warehouses actually run.
Fulfillment design is high-stakes and largely blind. The tooling that's supposed to de-risk it creates three problems of its own:
Each design variant takes an engineer weeks to model — so teams evaluate a handful of options when the real design space has thousands.
The numbers inside the model are assumptions. Validating them against the real building is manual and rarely done, so the output is a guess in a lab coat.
The binding constraint often isn't the stage you'd expect — and you find it after the building is up, when fixing it costs millions instead of a re-run.
Flow Cast Tech treats a warehouse as a routing network, not a line — because that's what it is. Here's exactly what it does:
Lay out nodes and routing and the discrete-event model generates itself. Change a branch and it rewires instantly — so you test thousands of variants instead of three.
It ranks nodes by how heavily traffic actually routes to them, not by raw capacity. In our default model the smallest node (Pack-Oversize, 216/hr) is fine, while a node with 4× the capacity is the true bottleneck because it carries 85% of the flow. A linear model gets this backwards.
Adjust capacity, re-simulate in a blink, watch the number change. One click finds the binding node and relieves it — in the demo, 1,037 → 1,180 orders/hr from four added stations in the right place.
Service times and split ratios are learned from real warehouse telemetry across deployments — so the prediction matches the building, and gets sharper with every site.
The simulator on this site is a real, running discrete-event engine with a live network diagram. Inputs are placeholder data; the math is real.
No "contact us for pricing" mystery. These are real starting points; the right fit depends on how many facilities you design and operate.
A 30-minute call: we'll look at one of your facilities or a design you're weighing, and show you the constraint live. No deck.
Prefer email? hello@flowcast.example