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?"
• "What is our current picker productivity and how is it trending?"
• "What is the optimum AMR fleet size?"
• "How many pickers do we need today for on-time picking and staging?"

These are the challenges warehouse engineers face every day. And if you’re a warehouse engineer, you know that performing analysis usually involves manually compiling reports from all your different data silos: WMS, LMS, ERP, and more. Even if you have all this data (which you might not), and even if you can get to it easily (which you often can’t), decisions might still be made based simply on what has worked in the past, what another person recommends, or just on gut instinct—regardless of whether or not it might cost more further down the road.

That’s where Digital Twin Studio^® comes in, empowering warehouse engineers to ditch the guesswork, say goodbye to spreadsheets, and perform smarter, real-time, data-driven warehouse optimization with the perfect blend of simulation, AI, and Digital Twin technology.

Digital Twin Studio^® helps fine-tune your warehouse by leveraging your entire software stack

Most warehouse optimization tools don’t actually use your real data — they convert it into rough probability estimates. Instead of using actual WMS transactions, they rely on averages and assumptions to model warehouse behavior, which can miss most of the critical bottlenecks and variation you’d see in the real world.

Digital Twin Studio^® unlocks a new level of data visibility and warehouse analysis: no limits on connectivity, no silos, and no basic guestimation. Your Digital Twin is a living, breathing model of your your warehouse: every SKU, rack location, and conveyor belt. No more drowning in spreadsheets or hoping one change won’t ripple through the rest of your facility. Your Digital Twin pulls directly from your WMS, ERP, automation systems, and even IoT devices to evolve with your data, while AI and machine learning reveal exactly where, how, and when improvements will pay off.

Historical Replay with Simulation

Digital Twin Studio^® can replay a historical snapshot of your warehouse, whether it’s a single shift, the past two weeks, or your entire peak season. Replay your data in the simulation environment to see where things backed up, which bays were hot, and what you could have done differently.

Forecasting & Risk Mitigation

Looking back on warehouse activities is useful, sure, but what if you could look ahead and identify potential issues before they occur? Digital Twin Studio^® enables data-driven forecasting, letting you look ahead and optimize before a shift, before a snowstorm, before the holiday season, or before expanding the warehouse. Leverage upcoming pick orders, demand forecasts, or inventory to pinpoint your schedules, perfect your layouts, and set your warehouse strategy months and years into the future.

Real-Time Visibility & Reporting

Ok, you’ve gone over last Tuesday’s picks and found that opening another dock door would have reduced some of that backup at the outbound area. But what about what’s happening on the floor right now? Are we on track to finish our picks by EOD? Are we maintaining our target UPH?

Digital Twin Studio^® takes data connectivity to the next level by loading warehouse data in real-time, mirroring warehouse activities as they happen, and dashboarding the live KPIs that matter most to your operation.

Your Digital Twin uses AI to turn data into decisions

Most warehouse optimization tools don’t actually use your real data — they convert it into rough probability estimates. Instead of using actual WMS transactions, they rely on averages and assumptions to model warehouse behavior, which can miss most of the critical bottlenecks and variation you’d see in the real world.

Once your warehouse data is connected, Digital Twin Studio’s AI uncovers patterns and relationships that would be impossible to catch with spreadsheets or static reports. It looks at every transaction, every pick, every delay — not in isolation, but in context — and forecasts what’s likely to happen next under a variety of real-world conditions.

So, instead of manually analyzing last month’s trends and making gut-based decisions, you can more quickly reach the point of saying:

Let’s say your team is onboarding a new product line with slower-moving SKUs and increased returns. Digital Twin Studio^® can dynamically compare that scenario against historical performance from similar product types, customer demand patterns, and staffing levels — then show you the impact on pick paths, staging areas, and labor utilization. From there, it shows you which slotting changes, schedule tweaks, or automation triggers will actually make a difference.

The best part? These insights aren’t buried in raw data or locked behind code. Digital Twin Studio gives you a clear, data-backed view of what’s happening, what’s likely to happen next, and what actions will make the biggest impact. It helps warehouse engineers cut through the noise, validate ideas faster, and make confident, informed decisions without the hours spent wrangling spreadsheets. Whether you're coordinating with operations, planning, or leadership, your Digital Twin gives you the evidence to back up your recommendations, and the guidance to help your team move forward with confidence and clarity.

Smarter warehouses. Fewer spreadsheets. No guesswork

Digital Twin Studio^® isn’t just about running simulations or generating reports. It’s about helping warehouse engineers feel confident in their decisions — whether they’re optimizing slotting, validating automation, or planning for growth.

Because an optimization tool shouldn’t just replace experts: it should help you and your team be more connected, more confident, and stay competitive years into the future.