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In the last decade, simulation software as a tool for managing and controlling business
processes has received a lot of attention. Many of the new software features allow businesses to
achieve better quality results using optimisation, such as genetic algorithms. This article describes the
use of modelling and simulation in shipment and sorting processes that are optimised by a genetic
algorithm’s involvement. The designed algorithm and simulation model focuses on optimising the
duration of shipment processing times and numbers of workers. The commercially available software
Tecnomatix Plant Simulation, paired with a genetic algorithm, was used for optimisation, decreasing
time durations, and thus selecting the most suitable solution for defined inputs. This method has
produced better results in comparison to the classical heuristic methods and, furthermore, is not
as time consuming. This article, at its core, describes the algorithm used to determine the optimal
number of workers in sorting warehouses with the results of its application. The final part of this
article contains an evaluation of this proposal compared to the original methods, and highlights what
benefits result from such changes. The major purpose of this research is to determine the number of
workers needed to speed up the departure of shipments and optimise the workload of workers.