Case Study Improve Patient Flow, Reduce Length-of-Stay, and Optimize Providers with Digital Twin Studio® Problem statement A mid-size hospital (211 Beds, 11 OR Rooms, 25 ED Beds) was experiencing significant operational challenges that impacted patient care and resource efficiency. Emergency Department (ED) crowding had intensified, leading to prolonged ED-to-inpatient boarding times and increased risk of patients left without being seen (LWBS). Inpatient units faced highly variable lengths of stay (LOS), which disrupted the scheduling of elective procedures and contributed to under-utilization of operating rooms (ORs). Additionally, poor visibility into downstream bottlenecks—such as delays in imaging, lab processing, and post-acute placement—combined with inefficient staff deployment, further strained hospital operations. Read more

Case Study nGroup: Driving Efficiency and Client Confidence with Warehouse Digital Twins Background nGroup, a leading 3PL provider, manages a network of facilities serving diverse clients with complex warehousing needs. One of its flagship operations in Lebanon, OH is a multi-client reverse logistics facility—a highly dynamic environment where incoming goods vary widely in condition, packaging, and processing requirements. This variability makes efficient space utilization, labor planning, and workflow design particularly challenging. The Challenge nGroup faced several operational pain points: Dynamic Client Mix – Clients come and go frequently, each with unique layout and process needs. High Complexity – Reverse logistics requires additional processing beyond traditional receiving and shipping. More Read more

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Case Study: High Mix, Low Volume Manufacturing Optimization with Digital Twin Studio Problem Statement A leading high mix, low volume electronics manufacturer faced mounting inefficiencies across its production lines. Challenges included unpredictable cycle times, excess WIP (work-in-process), inconsistent product quality, and limited visibility into scheduling bottlenecks. With growing customer demand for customization and quick turnaround, traditional methods proved inadequate. Background Established in 1992, the company operates in a competitive, fast-moving market where adaptability and precision are essential. While they had implemented lean practices and used traditional planning tools, these methods lacked the dynamic, real-time decision-making capabilities needed for modern high mix, low volume manufacturing. Leadership identified digital transformation as a strategic priority to maintain market relevance and improve responsiveness. Read more

How Digital Twin Studio® Helps Warehouse Engineers Make Smarter Choices Without Spreadsheets Sometimes, warehouse management and continuous improvement can feel like a guessing game. "Which slotting, putaway, and replenishment configuration gives us the best UPH?” "How should I adjust my waving and pick releases to achieve the best efficiency every day?" “How do I zone my warehouse to optimize AMR usage?" Read more