Warehouse Digital Twins: Optimize Your Warehouse Design

What is a Warehouse Digital Twin?

A warehouse digital twin is a dynamic, virtual replica of a physical warehouse that uses real-time data to mirror and emulate the physical environment. Unlike traditional simulations, which primarily handle discrete components of a system design, digital twins offer a comprehensive, real-time view of all warehouse operations, enabling more precise and predictive management. The emulated environment attempts to recreate the real environment utilizing real-time data, as opposed to a simulation environment, which runs through numerous versions of inputs to explore possible output states.

Components of a Digital Twin

Physical Assets

These include all the tangible elements within the warehouse, such as storage, forklifts, conveyors, AS/RS, and other automated systems. Each physical asset is mirrored in the digital twin environment, providing a detailed and accurate representation.

Data Collection

Whenever a retrofit (i.e., brownfield) implementation is planned, real-time sensors in the warehouse are utilized to capture data. This data is fed into the digital twin to offer realistic working rates, volumes, and other performance metrics. Utilizing real-world values offers the most representative emulation environment. 

Emulation Models

These models replicate the warehouse operations and can be used to emulate different scenarios. These can include stress-testing the system to identify any fatal flaws in the design, testing various components to ensure the design is within desired limits, and emulating stages in the implementation schedule. This ability allows design engineers to test their design with confidence that the emulated environment captures the expected outcome in reality as closely as possible.

Analytics and Reporting

The emulation environment of a digital twin allows quantitative analysis. Running through several implementation scenarios, emulating peak day, and other behavior allows emulation to analyze the expected system behavior. Reports and detailed analytics are available to the design engineers to identify bottlenecks, and redesign any components not behaving as expected. 

AI Integration

Artificial intelligence (AI) is integral to the functionality of digital twins. AI technologies enhance the digital twin by providing advanced analytics, predictive capabilities, and automated decision-making processes.

Data Collection and Analysis

A warehouse digital twin utilized in a retrofit collects vast amounts of data from various sources, including sensors, RFID tags, and IoT devices. AI technologies can processes and analyzes this data to extract actionable insights, such as identifying current state inefficiencies, locating bottlenecks in the operation, , and optimizing the design based on system flow and volume.

Benefits of Utilizing a Warehouse Digital Twin

Implementation Efficiency

By emulating the future state and any intermediate states of the operation, implementation teams can have confidence that their system will perform as expected. This provides efficiency in any retrofit design by allowing testing of the key systems and any stages of the operation between the current and final state.

Cost Reduction

Digital twins help minimize wasted implementation effort and optimize resource usage. Fully testing various scenarios allows implementation teams to plan for the impact of various design stages and provide proper expectations to the operation to allow headcount minimization. This can also minimize the controls engineering required to get the system up and running post-implementation, reducing the overall cost of the project. 

Enhanced Decision-Making

With real-time monitoring and forecasting capabilities, digital twins improve strategic planning and risk mitigation. Emulating the environment and providing quantitative feedback allows data to be used in decision making and providing realistic effects of decisions, sometimes in real-time.

Use Cases for Digital Twins in Logistics

Warehouse Design Emulation

Emulation can be used for warehouse layout optimization and to test new processes and designs. This is especially important for new designs such as greenfields and retrofits. Digital twins help in predicting system performance and identifying potential bottlenecks before implementation.

Warehouse Automation

Digital twins can play a crucial role in warehouse automation studies. By emulating the system before building anything real, key impacts can be fully understood and the operational impact can be analyzed, providing insight and confidence to any automation decisions.

Predictive Analysis

Digital twins enable predictive analysis, which can forecast inventory needs, identify potential disruptions, and optimize supply chain operations before building them in reality. This can allow businesses time to plan, prepare, and mitigate risk.

Steps to Implementing a Warehouse Digital Twin

1. Initial Assessment

Evaluate current warehouse operations and identify key areas for improvement. This step involves a thorough analysis of existing processes and infrastructure. By partnering with Maveneer, you can understand what aspects of your current operations need enhancement or automation. Our experts will conduct a comprehensive assessment of your organization’s supply chain, identifying inefficiencies, potential bottlenecks, and opportunities for optimization. 

2. Design Engineering

Selecting the right technology for the operation is pivotal to have a successful implementation. The design engineering process includes planning, deployment, and rigorous analysis to ensure meaningful designs are utilized that benefit the operation in a meaningful way.

3. Development and Implementation

Once you have a design in place, significant effort is required to build and fully calibrate the emulation environment. This requires 3D drawings of existing infrastructure, links to appropriate operational data, calibration to known operational behaviors, and thorough testing of all code utilized to run the operation.

4. Testing and Analysis

Once the emulation environment has been properly built and verified, it is time to test and analyze the impact of the design. There may be modifications or iterations to the design, which can be studied using the emulation and fully realize the impact of key design decisions. Any design stages to the implementation are fully tested and analyzed and final reports of the impacts can be developed for proper business planning.

Optimize Implementation and Minimize Risk with Warehouse Digital Twins

Implementing a warehouse digital twin in the design process of any warehouse upgrade can severely reduce risk, stress-test the new environment, and reduce implementation timelines. Thus, reducing costs, and enhancing decision-making capabilities. Contact us to learn more about how Maveneer can help you optimize your operations.