In a world facing unprecedented challenges, such as climate changes and growing social problems, the pharmaceutical industry must ensure that its supply chains are environmentally sustainable and resilient, guaranteeing access to key medications even when faced with unanticipated disruptions or crises. The core goal of this work is to develop an innovative simulation-based approach to support more informed and effective decision making, while establishing reasonable trade-offs between supply chain robustness and resiliency, operational efficiency, and environmental and social concerns. Such a decision-support system will contribute to the development of more resilient and sustainable pharmaceutical supply chains, which are, in general, critical for maintaining access to essential medicines, especially during times of crises or relevant disruptions. The system will help companies to better manage and design their supply chains, providing a valuable tool to achieve higher levels of resilience and sustainability. The study we conducted has two primary contributions that are noteworthy. Firstly, we present a new advanced approach that integrates multiple simulation techniques, allowing for the modeling of highly complex environments. Secondly, we introduce a new conceptual framework that helps to comprehend the interplay between resiliency and sustainability in decision-making processes. These two contributions provide valuable insights into understanding complex systems and can aid in designing more resilient and sustainable systems.

Effective warehouse management plays a pivotal role in optimizing supply chain performance, particularly in high-demand, time-sensitive environments. This study introduces a simulation-based decision support system designed to improve the management of Picking-By-Line (PBL) operations in cross-docking distribution centres. Developed in FlexSim and calibrated with empirical data from an industrial case study, the model replicates real-world warehouse conditions and is validated against observed operational performance. The tool supports warehouse managers in evaluating and comparing operational strategies, such as dynamic storage allocation policies and picker routing constraints, with the goal of reducing operator travel distances, mitigating congestion, and enhancing overall efficiency. A key contribution of this work is the integration of congestion-sensitive performance indicators that allow for a detailed analysis of the trade-offs between travel efficiency and localized congestion—an aspect often overlooked in traditional optimization methods. This study demonstrates the value of simulation as a scalable and realistic decision-support tool for optimizing PBL operations in complex and variable environments where human movement is a major cost and performance driver. The proposed tool bridges the gap between theoretical modelling and practical implementation, offering actionable insights for warehouse layout, space utilization, and resource allocation.