Gemstone Systems delivers end-to-end warehouse automation engineering — from simulation modeling and AutoCAD layout design to picking system integration, controls architecture, and cold chain flow analysis. We've done this work globally. We know what moves the needle.
We don't work in isolation. Layout, automation, controls, simulation, and reporting all connect. We engineer them that way from the start.
We model your operation before you build it — or rebuild it. Using simulation development tools, we replicate real-world warehouse behavior: order profiles, slotting strategies, labor, throughput peaks, and bottlenecks. The result is a model you can stress-test, optimize, and hand to leadership with confidence. We've applied this on facilities across multiple continents, from retrofit projects to ground-up DC design.
From conceptual flow to production-ready drawings. We produce AutoCAD facility layouts for new builds, expansions, and retrofits — incorporating equipment placement, aisle configuration, dock positioning, electrical routing, and technology infrastructure. Every layout is designed around your actual operation, not a template.
Each pick. Case pick. Pallet automation. We design picking systems that work in concert — not in isolation. At Byhalia, we designed each-picking automation alongside a pallet picking system as a unified, integrated solution with controls architecture woven throughout. That systems-thinking approach is what separates real automation from expensive conveyors.
Automation without controls is just hardware. We tie the mechanical and the digital together — PLC programming, WMS/WES/WCS integration, sensor logic, and system-wide controls architecture. Flow efficiency only materializes when the controls layer is designed with the same rigor as the physical layout.
Not every operation needs robotics. Not every robotics pitch is worth the price tag. We provide vendor-agnostic technology assessments — evaluating automation options, WMS platforms, sortation systems, and material handling equipment against your actual volume, SKU profile, and growth trajectory. We've been on-site globally to do exactly this.
Data exists in every warehouse. Most of it sits unused. We develop custom reporting tools and operational dashboards that surface what actually matters — productivity by zone, throughput vs. labor, order cycle time, dock-to-stock performance. Our work on the Kargo Towers reporting platform is a direct example of what purpose-built operational intelligence looks like.
These aren't theoretical engagements. Each project represents real facilities, real constraints, and real outcomes — delivered on-site and on scope.
Cold chain distribution has constraints that standard warehouse simulation ignores — temperature zone integrity, dwell time sensitivity, carrier sequencing, and compliance requirements at every handoff. We've built simulation models specifically for this environment, modeling who gets what product, where it goes, and how the network handles volume and disruption.
We bring genuine technical depth — not vendor presentations. Our team works across simulation platforms, AutoCAD, controls systems, and custom development to deliver solutions that are actually buildable and maintainable.
Production-grade facility layouts, electrical drawings, technology infrastructure plans, and equipment placement diagrams. Every drawing built to be construction-ready.
We work across leading discrete event simulation environments to model warehouse operations with fidelity — not just diagrams. Real behavior, real constraints, real output.
From conveyor controls to sortation systems and picking automation — we architect and integrate the controls layer that makes automation actually function as designed.
Purpose-built operational dashboards and reporting platforms — connected to your actual data sources, built around your actual KPIs. No off-the-shelf compromise.
Goods-to-person, each pick, pallet automation, sortation — we design systems as integrated solutions, not standalone equipment purchases.
Evaluating, specifying, and integrating warehouse management, execution, and control systems — including WES development and design from the ground up, aligned to your automation footprint and operational requirements.
Every engagement follows a clear path from discovery to delivery. We don't disappear after the presentation — we're there through implementation.
Whether you're designing a new DC, optimizing an existing facility, evaluating automation, or need a simulation built before you commit capital — we want to hear about it. Engagements are project-based. No retainer required to get started.