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WAREHOUSE DIGITAL TWIN

DIGITAL TWIN STUDIO®

Powered By AI/ML

 

Warehouse Digital Twin

Experience your warehouse—virtually.

A warehouse digital twin lets you emulate your operations with unmatched depth and precision. Combining historical and real-time data, it reveals hidden inefficiencies, validates process changes, and predicts delays and disruption before they hit the floor. From slotting and labor planning to automation and throughput, the digital twin delivers insights that optimize costs and performance over the long term.

Warehouse Digital Twin

Digital Twin Studio® creates a virtual replica of the Live Warehouse including racking, picking, automation, staging, receiving, put-away and replenishment. The Digital Twin contains all of the constraints of the actual warehouse, and behaves similarly to the live operation.

Data-Driven Warehouse Digital Twin

takes the implementation to the next level by allowing the Digital Twin to load actual data sets from the WMS / WES / SAP and perform predictive analytics on the warehouse operation. A Data-Driven Digital Twin™ automates the analysis of historical performance, improve current operation and better plan for expansion and future operations, in real-time.
Real-Time Digital Twin

Benefits of Data-Driven Digital Twin

 

Advantages of a Data-Driven Digital Twin™ for Warehouse:

Slotting Intelligence

Put every SKU in its most profitable place.

Your Digital Twin continuously analyzes SKU velocity, pick paths, and congestion to proactively test, identify, and recommend optimal slotting strategies. By validating changes against live operational data, warehouse leaders can increase throughput, reduce travel time, and delay or eliminate costly expansion projects.

Warehouse digital twin with auto-store
labor planning

Labor Planning

Align Workforce Needs with Real Demand.

Your Digital Twin forecasts labor requirements by shift, zone, and task type—balancing workload across the operation. Run what-if scenarios to test new schedules, evaluate automation’s impact on staffing, or adapt to seasonal volume spikes. Know exactly where and when your people are needed to minimize overtime and kill idle time.

Automation ROI

Validate Technology Investments Before You Buy.

Before committing capital, use your Digital Twin to evaluate different automation options under real operational conditions. From AMRs to AS/RS systems, each scenario quantifies the expected impact on throughput, labor efficiency, and cost per order. Confidently justify investments with a proven business case backed by real data.

warehouse pick module digital twin
Warehouse Digital Twin with Racks

Dock & Flow Optimization

Keep Goods and Information Moving Seamlessly.

By connecting to WMS, TMS, IoT data, and more, your Digital Twin visualizes every inbound and outbound movement in real-time. Bottlenecks and imbalances are identified instantly, and predictive models test potential improvements offline. The result? Smoother flow, shorter dwell times, and more predictable dock-to-stock performance.

Boost Warehouse Efficiency - Refine Facility Layout and Design

  • Optimize Warehouse Layout: Design your warehouse layout to minimize travel time and streamline the flow of goods.
  • Implement Lean Practices: Adopt lean warehousing principles to eliminate waste and improve processes. This includes reducing unnecessary movements, optimizing inventory levels, and continuously improving workflows.
  • Use Technology: Incorporate a Warehouse Management System (WMS) to automate and optimize inventory management.
  • Enhance Inventory Management: Regularly review and update inventory practices to ensure accuracy and reduce stock outs or overstock situations.
  • Improve Order Picking: Streamline the order picking process by using methods such as batch picking, zone picking, or wave picking.
  • Train and Empower Employees: Provide regular training to employees on best practices and new technologies.
  • Monitor Performance Metrics: Track key performance indicators (KPIs) such as order accuracy, inventory turnover, and picking efficiency.
warehouse - our Solutions
warehouse optimization

Optimizing Conveyor Design to Reduce Congestion

  • Strategic Layout Planning: Design the layout to minimize bottlenecks and ensure smooth flow of goods.
  • Implementing Advanced Technologies: Use automated systems like Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) to streamline material handling and reduce human traffic.
  • Dynamic Routing Systems: Incorporate dynamic routing algorithms that can adjust paths in real-time based on current congestion levels.
  • Regular Traffic Analysis: Conduct regular traffic flow analysis to identify and address congestion points.
  • Efficient Scheduling: Stagger work shifts and schedule deliveries during off-peak hours to avoid congestion.
  • Employee Training: Train employees on best practices for material handling and traffic management. Empower them to identify and report congestion issues.

Improve Material Handling and Fleet Sizing while Conducting Distribution Center Network Analysis

  • Create a Digital Twin: Develop a virtual model of your warehouse using digital twin technology. This model should replicate the physical characteristics and behavior of your warehouse, including layout, equipment, and workflows.
  • Simulate Material Handling Processes: Use the digital twin to simulate various material handling processes. This includes the movement of goods, the interaction between different systems (e.g., conveyors, AGVs), and the flow of materials through the warehouse.
  • Analyze Fleet Sizing: Determine the optimal size and configuration of your material handling fleet. The digital twin can help you simulate different fleet sizes and configurations to find the most efficient setup for your operations.
  • Conduct Network Analysis: Use the digital twin to perform a comprehensive analysis of your distribution center network. This includes evaluating the placement of distribution centers, the flow of goods between them, and the overall efficiency of the network.
  • Optimize Layout and Design: Continuously refine the layout and design of your warehouse based on insights gained from the digital twin.
  • Implement Real-Time Monitoring: Integrate real-time data from sensors and IoT devices into the digital twin.
  • Scenario Testing: Use the digital twin to test various “what-if” scenarios.
warehouse optimized slotting
warehouse flow

Enhance ASRS, AGV, and STV Capacity Planning to Validate and Design Automation Systems

  • Bottleneck Identification - Use simulation data to pinpoint bottlenecks in the production line. Optimize task sequencing to minimize downtime. Implement targeted improvements to alleviate bottlenecks.
  • Process Flow Analysis - Visualize and evaluate the entire production process flow. Identify non-value-added activities and streamline processes. Enhance overall process efficiency and productivity.
  • Performance Metrics - Track key performance indicators (KPIs) such as throughput, cycle time, and utilization rates. Compare simulated performance against benchmarks and goals. Use data-driven insights to guide decision-making

 

Looking for more Information

Digital Twin Studio® bundles the most powerful tools and offerings from CreateASoft: familiar look and feel of Simcad, combining the patented 64-bit multithreaded engine with the latest AI and ML technology.

Talk to our team today

Get more information

Applications of Digital Twin Studio®

image Warehouse Digital Twin

Visualize live data from your WMS & RTLS,
Proactive alerts for delays and congestion,
Optimize AGV/AMR/ASRS logic in real-time Warehouse Digital Twin
image Manufacturing Digital Twin -

Visualize live data from your MRP/ERP & RTLS,
Proactively manage production schedules, cost per unit, and WIP inventory,
Optimize future state in real-time Manufacturing Digital Twin
image Healthcare Digital Twin -

Visualize live data from your EMR and RTLS,
Monitor schedules and patient flow in real-time,
Proactive reductions in LOS & LWBS Healthcare Digital Twin

Three powerful tools to bring your Digital Twin to life.

Digital Twin Off-Line Modeling & Analysis

Digital Twin Studio® Desktop lets you model your workflows. un-silo your data, and unlock cost savings with AI and Machine Learning.

Digital Twin Studio® Desktop

Real-Time Digital Twin Monitoring and Analysis

Digital Twin Studio® Live enables total visibility with real-time data connectivity, facility monitoring, KPI reporting, and Web-Enabled custom dashboards.

Digital Twin Studio® Live

Real-Time AI-Powered Optimization and Insights

Digital Twin Studio® Intelligence is real-time regenerative AI for your Digital Twin, working around the clock to navigate around disruption.

Digital Twin Studio® Intelligence
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  • 3909 75th St. Ste 105,
             Aurora, IL 60504
  • (630) 851-9474
  • (630) 566-0756
ABOUT US

With over 30 years of industry experience, we are proud to support over 3,600 clients worldwide, helping them achieve sustainable competitive advantages through advanced digital twin technology.

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