One factor that has to be taken into account is the "social" one, i.e. how can we enforce that the ultra-fast amazingly optimal sitting scheme will be used.

Let's conduct a thought experiment. My grandma (that has difficulty hearing) is boarding a plane. Try explaining to her, in a sensible and efficient manner that only the people at the windows should get in first.

Ok, maybe my grandma is an extreme example. But think of a first time flyer. Lots of people would be confused.

Also, as already stated, people that travel together sit side by side. Are you going to split the young couple of newly weds during boarding? Is that really sensible? Or the mother and her five kids?

The main takeaway that I get is that you should let people get in without any pre-ordering. Unless you can devise a socially acceptable way to enforce outside-in boarding, that is. I'm not.

You see, the bottom line for me is that simulations are really valuable, but not taking into account the human factors involving the business, how the people actually consume your product, you can have great ideas that work on excel and flunk marvelously on the market.