Featured Case Study

Project

Digital Twins for Warehouse & Logistics

Partner
Sector Warehousing & Supply Chain Logistics

Warehouse & Logistics

ROI & Business Impact

Improvement in overall warehouse efficiency

15-25%

Reduction in total operational costs

20-30%

Reduction in asset maintenance costs

25-35%

Reduction in turnaround time

20-30%

Investment & Costs

Pilot$50,000 – $75,000
Single WarehouseTBD
Multiple WarehousesTBD
Multiple SitesTBD

Investment Recovery

Typical payback period: 12-18 months
Ongoing operational savings compound annually
5-year NPV: 200-400% of initial investment

Challenges

Operational Inefficiencies in Modern Warehousing

Fragmented Inventory Visibility

Inventory data spread across multiple systems slows accurate stock tracking.

Inefficient Workflow Movements

Suboptimal routes and layouts increase travel time and reduce throughput.

Equipment Downtime Risks

Material-handling systems lack predictive monitoring, causing unexpected stoppages.

Limited Operational Insights

Absence of real-time analytics hampers decision-making and performance tuning.

Traditional warehouse tools cannot provide unified visibility across assets, workflows, and real-time operations.

100%

Operational Transparency Across Warehouse & Logistics Flows

Why Digital Twins

Transforming Warehouse & Logistics Efficiency

Operations

Real-time visibility into assets, workflows, and floor activities.

Decisions

Data-driven insights for faster, more accurate operational decisions.

Costs

Reduced downtime, fewer errors, and optimized resource utilization.

Scalability

Easily extends across multiple warehouses and logistics networks.

Solution

Overview

Our Digital Twin Solution is a patented browser-based platform specifically designed for process twins, transforms existing geometric data into interactive 3D environments that integrate real-time IoT sensor data, enterprise systems, and AI analytics

Solution

A Unified Digital Twin for Warehouse & Logistics Operations

Combining 3D, IoT, and AI in a no-code platform to create intelligent warehouse twins that optimize workflows and asset utilization.

WMS/TMS
AI/LLM Data
Automation Controllers
Video Systems
Historical Data
IoT/RFID/Sensors
Assets/ERP

WMS/TMS
AI/LLM Data
Automation Controllers
Video Systems
Historical Data
IoT/RFID/Sensors
Assets/ERP

End-to-End Data Fusion

Integrates IoT sensors, WMS, ERP, and conveyor telemetry into one operational model.

Inventory Tracking & Verification

Provides real-time visibility of stock levels, movement, and discrepancies.

Equipment Performance Analytics

Monitors conveyors, sorters, forklifts, and AMRs for efficiency and condition.

Workflow & Route Optimization

Simulates picking paths and automates task allocation for faster fulfillment.

3D Warehouse Visualization

Creates a high-fidelity digital environment of racks, zones, and equipment.

Predictive Maintenance AI

Forecasts failures and schedules maintenance to reduce unplanned downtime.

Operational Dashboards

Displays KPIs, alerts, and performance trends for supervisors and managers.

Scenario Modeling

Tests changes in demand, layouts, labor, and equipment before real-world execution.

Our USP

Mass Accessible Digital Twins

	Traditional Solutions	Our Breakthrough
Accessibility barrier	Siloed Solutions	Browser Application
Creation complexity	Requires 3D Designers/ Developers	No-code platform
Hardware requirements	GPU Servers ($250k-$750k)	No GPUs or heavy servers needed
Deployment time	6 to 9 Months	6 to 9 Weeks
Device limitations	PC/Desktop or specific hardware	Access on any device
Technical dependencies	Constant IT support required	Self-service platform
Annual pricing per twin	$100k-$1M	$25k-$80k

Benefits of Digital Twins for Warehouse & Logistics

Equipment Health Monitoring

Equipment condition dashboards
Historical performance insights

Description

Real-time monitoring of conveyors, sorters, forklifts, and AMRs.
Business Impact

Reduces unplanned downtime and improves equipment reliability.
Key Elements

Sensor data fusion, anomaly alerts, performance trends.

Predictive Maintenance of MH Equipment

Failure probability insights
Optimized maintenance scheduling

Description

AI-driven failure prediction for material-handling equipment and automation lines.
Business Impact

Minimizes maintenance costs and prevents operational stoppages.
Key Elements

Degradation modeling, risk scoring, and predictive analytics.

Inventory Accuracy and Optimization

Live stock-level visibility
Intelligent replenishment recommendations

Description

Tracks inventory in real-time across racks, zones, and staging areas.
Business Impact

Improves order accuracy and reduces stock discrepancies.
Key Elements

3D inventory mapping, scan/RFID integration, demand insights.

Benefits of Digital Twins for Warehouse & Logistics

Real-time Warehouse Dashboard

Real-time performance monitoring
Cross-system data fusion

Description

Provides a unified view of inventory, equipment, workforce, and operational KPIs across the warehouse.
Business Impact

Improves situational awareness and accelerates decision-making in daily operations.
Key Elements

Live KPIs, alerting framework, and multi-layer operational views.

Warehouse Layout Optimization

Optimized rack and zone design
Travel-time and congestion insights

Description

Simulates rack layouts, storage zones, and traffic paths to maximize space efficiency and reduce travel time.
Business Impact

Enhances throughput and improves picking, replenishment, and put-away operations.
Key Elements

3D layout modeling, flow simulation, and scenario testing.

Order-Fulfilment Optimization

Intelligent pick-batch grouping
Real-time task allocation

Description

Optimizes picking sequences, batching, and routing for faster and more accurate order fulfillment.
Business Impact

Reduces cycle times and increases order accuracy during high-volume periods.
Key Elements

Pick-path optimization, workload balancing, and task automation.

Benefits of Digital Twins for Warehouse & Logistics

Peak Season and Capacity Planning

Optimal staffing and shift planning
Inventory and throughput predictions

Description

Simulates inventory volume, labor demand, and equipment load to prepare for peak seasons.
Business Impact

Prevents bottlenecks and ensures smooth operations during high-demand periods.
Key Elements

Demand forecasting, workload modeling, and scenario simulation.

Transportation and Delivery Optimization

Intelligent dock and dispatch scheduling
Real-time route optimization

Description

Optimizes outbound routing, dock scheduling, and delivery planning using live operational data.
Business Impact

Reduces transit times, improves dispatch accuracy, and cuts transportation costs.
Key Elements

Route modeling, load planning, and vehicle utilization analytics.

Warehouse Safety and Compliance

Safety incident and near-miss alerts
Compliance monitoring dashboards

Description

Monitors safety zones, equipment interactions, and worker movement to identify hazards.
Business Impact

Reduces accidents, improves compliance, and enhances workforce safety.
Key Elements

Geofencing, PPE tracking, and hazard detection.

Benefits of Digital Twins for Warehouse & Logistics

Automated Alert Incident and Response

Fault and hazard notifications
Smart corrective action suggestions

Description

Automatically detects anomalies, equipment faults, safety violations, and workflow disruptions in real time.
Business Impact

Improves response time, reduces downtime, and minimizes operational risk.
Key Elements

Real-time alerts, automated triggers, and incident workflows.

Customer Experience and Delivery Tracking

Milestone-based delivery tracking
Customer-facing status updates

Description

Tracks order status, delivery SLAs, and shipment movement across the fulfilment cycle.
Business Impact

Enhances transparency and boosts service quality for customers and partners.
Key Elements

SLA monitoring, delivery analytics, and order visibility.

Sustainability and Compliance

Energy and carbon footprint insights
Automated compliance checks

Description

Monitors energy use, emissions, safety rules, and regulatory compliance across warehouse operations.
Business Impact

Supports ESG goals, reduces energy waste, and maintains safety standards.
Key Elements

Emission analytics, safety metrics, and compliance monitoring.

Benefits of Digital Twins for Warehouse & Logistics

Inbound Dock Door Assignment View

Intelligent dock-door recommendations
Real-time unloading status

Description

Provides real-time visibility of inbound trailers, dock availability, and unloading priorities.
Business Impact

Improves dock utilization, reduces wait times, and accelerates receiving.
Key Elements

Dock scheduling, load prioritization, and trailer flow tracking.

PO/ASN Receiving (Mass, RF, Return)

Automated item verification
Exceptions and variance alerts

Description

Digitizes the full receiving process including bulk receiving, RF-scanning, and returns handling.
Business Impact

Increases receiving accuracy, reduces processing time, and minimizes discrepancies.
Key Elements

RFID/scan data capture, bulk receiving logic, and return processing flows.

Putaway Visualisation

Smart location recommendations
Real-time space availability insights

Description

Visualizes optimal putaway locations based on inventory type, demand, and space availability.
Business Impact

Enhances storage efficiency and shortens travel time for picking and replenishment.
Key Elements

3D rack mapping, slotting intelligence, and demand-based placement.

Benefits of Digital Twins for Warehouse & Logistics

Waving Efficiency

Dynamic wave generation
Capacity-aware batching

Description

Optimizes wave planning and order grouping based on real-time demand and pick-path performance.
Business Impact

Increases throughput while reducing congestion and operational delays.
Key Elements

Wave simulation, order clustering, and workload balancing.

Pack Station

Real-time pack-station monitoring
Automated quality validation

Description

Digitally tracks packing tasks, station workloads, and packaging accuracy in real time.
Business Impact

Improves packing speed, reduces errors, and enhances fulfilment quality.
Key Elements

Task orchestration, station utilization analytics, and accuracy checks.

Pallet Building

Optimal pallet layout recommendations
Automated palletization workflows

Description

Simulates pallet configurations to optimize stacking patterns, stability, and utilisation.
Business Impact

Reduces damage, improves loading efficiency, and enhances outbound processing.
Key Elements

3D pallet modeling, weight distribution analysis, and stacking logic.

Benefits of Digital Twins for Warehouse & Logistics

Cycle Counting (reporting, RF, adjustments)

Real-time count variance alerts
Seamless audit-ready reporting

Description

Automates cycle counting workflows with real-time RF-enabled updates and discrepancy reporting.
Business Impact

Improves inventory accuracy while reducing manual counting effort.
Key Elements

RF-based scanning, exception handling, and automated adjustment logs.

Slotting

Dynamic re-slotting recommendations
Pick-path efficiency insights

Description

Optimizes product placement by analysing demand, pick frequency, and movement patterns in real time.
Business Impact

Reduces travel time, boosts picking productivity, and enhances space utilization.
Key Elements

Heat maps, ABC analysis, and rule-based slot allocation.

Item Level Information

Full item-level traceability
Real-time location visibility

Description

Tracks each item with granular detail—including location, status, movement history, and availability.
Business Impact

Enables precision tracking, reduces search time, and minimizes loss or misplacement.
Key Elements

Digital item identifiers, real-time movement logs, and condition monitoring.

Business Model

Warehouse & Logistics Digital Twin

Feature	Basic	Plus	Pro
Application Complexity	Low	Medium	High
Level of Detail	LOD2	LOD3	LOD4
Workflows	4	10	no limit
Viewer Access	1 User	5 Users	10 Users
Editor Access	1 User	2 User	3 Users
Heatmap view	Yes	Yes	Yes
Real time IOT integration	Yes	Yes	Yes
RBAC	-	Yes	Yes
Alerts & Notifications	-	Yes	Yes
X-Ray View	-	Yes	Yes
Simulated Data Integration	-	-	Yes
Custom Branding	-	-	Yes
AI/LLM Integration	-	-	Yes
3rd Party API Integration	-	-	Yes
One-Time Cost for Process Twin Sandbox	-	-	-
Sandbox Development Duration	3-4 Weeks	4-6 Weeks	6-9 Weeks
Process Twin Platform Price (per month)	$750	$1500	$3000
Additional Viewer License (per month)		$100
Additional Editor License (per month)	Contact Us	$500	Contact Us