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Warehouse Simulation and Digital Twin Software

Transform your warehouse operations with real-time, data-driven insights

Say goodbye to outdated simulations and hello to Digital Twin Studio®. Our cutting-edge platform turns warehouse data into real-time actionable insights, streamlining your process flow and maximizing warehouse efficiency.

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Digital Twin Studio® Methodology: 4 steps to success

Warehouse optimization software should be simple. Digital Twin Studio® takes a unique approach to guide you along the four essential phases of your digital transformation.

  • Modeling
  • Analysis
  • Optimization
  • Go Live

Build your warehouse digital twin in weeks, not months

Model your warehouse in the patented drag-and-drop environment of Digital Twin Studio® with intuitive auto-build features, a low-code interface, and a built-in library of 3D assets.

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Emulate your warehouse’s software stack to leave no stone unturned

Emulate data for the upcoming shift, from yesterday’s picks, or from your entire peak season. Visualize your problem areas with built-in reporting and analysis tools.

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A patented neural network does the heavy lifting for full warehouse optimization

Let Digital Twin Studio® automatically attack areas for improvement, or easily define and compare custom scenarios to optimize slotting, scheduling, order releases, manpower, and more.

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Take things to the next level with real-time connectivity and machine learning

Connect live data and unlock remote visibility, up-to-the-moment KPI dashboards, and regenerative AI which continually forecasts and optimizes day-to-day operations automatically.

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Case Study: data-driven warehouse optimization with Digital Twin Studio®

Data-Driven Warehouse Optimization with Digital Twin Studio®
How a cold storage facility leveraged WMS pick sequences to optimize operations from inbound to outbound.

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Digital Twin Studio®: your complete Warehouse Optimization Toolkit

On-the-fly warehouse modeling

Build a precise, scalable Digital Twin of your warehouse in a matter of weeks. Our patented on-the-fly modeling allows you to capture every aspect of your facility, from complex racking layouts to conveyor systems, ensuring an accurate and adaptable representation.

Warehouse Simulation & Analysis

Simulate your warehouse processes with the patented, powerful simulation engine of Simcad DT®. Identify and resolve bottlenecks, test different picking/slotting strategies, and optimize order fulfillment paths to reduce travel time and improve throughput.

Integrated Software Stack Emulation

Emulate your entire warehouse software stack with Simcad DT® by integrating WMS, WES data, historical pick orders, and real-time slotting schedules. Test different replenishment strategies, order release sequences, and congestion points to refine your warehouse operations.

Real-Time Facility Monitoring

Transform your Digital Twin into a live operational dashboard with Digital Twin Studio® by connecting to your WMS, WES, and RFID systems. Monitor real-time activity, track picker efficiency, and get immediate insights into every corner of your facility, ensuring a truly dynamic warehousing experience.

AI Powered Lean Analysis

Leverage advanced machine learning and AI to monitor key warehouse metrics like value-added time, throughput, labor productivity, and cost per SKU. Get actionable insights to enhance your warehouse’s operational efficiency.

Predictive Forecasting & Proactive Alerts

Stay ahead of demand shifts with dynamic forecasting, predictive analytics and automated alerts. Use Digital Twin Studio® to analyze upcoming pick orders, identify potential congestion, and proactively adjust slotting and replenishment schedules to maintain peak efficiency.

warehouse overview

Modeling

 
Build your warehouse digital twin in weeks, not months

Build your model in CreateASoft’s patented drag-and-drop environment, complete with intuitive auto-build features, a low-code interface, and a built-in library of 3D assets for warehouse, manufacturing, healthcare, and supply chain modeling.

Analysis

 
Emulate your warehouse’s software stack to leave no stone unturned

Emulate demand data for upcoming production orders, WMS picks from the last two weeks, or every order from your entire peak season. Visualize your problem areas and bottlenecks with built-in reporting and analysis tools.

warehouse optimization

Optimization

 
A patented neural network does the heavy lifting for full warehouse optimization

Let CreateASoft’s patented data analysis and machine learning engines automatically attack areas for improvement, or easily define and compare custom scenarios to optimize the KPIs that matter most to you.

Go Live

Take things to the next level with real-time connectivity and machine learning

Connect live data with Digital Twin Studio® and unlock remote monitoring, up-to-the-moment KPI dashboards, and an intelligent regenerative AI which continually forecasts and optimizes day-to-day operations automatically.

warehouse - View live

DT Studio® Warehouse ROI

4%

INCREASE IN THROUGHPUT WITH SCHEDULING OPTIMIZATION

8%

DECREASE IN FACILITY CONGESTION

10%

INCREASE IN SPACE AVAILABILITY

Stay ahead of the curve with real-time insights. Digital Twin Studio® keeps an eye on your operations 24/7, alerting you to potential issues before they become problems. More visibility means more control—and more peace of mind. From seasonal spikes to unexpected surges, Digital Twin Studio® helps you plan for whatever comes your way. By analyzing trends and predicting demand, Digital Twin Studio® provides the support you need to keep shelves stocked and customers happy.

Our solutions provide a wide array of analytical tools, including scenario analysis, storage density evaluations, heat maps, and congestion analysis and much more. These tools provide comprehensive insights into various aspects of operations, allowing for detailed assessments and improved decision-making. Moreover, with our support for Discrete Pathed Entities (spatially aware models that have the capability to detect and avoid collisions), our solutions are designed to navigate their environment with a high level of precision, ensuring they can move efficiently while avoiding obstacles. And with support for both AGVs, AMRs, as well as manual forklift picking and slotting - DT Studio® provides versatility and flexibility in warehouse management simulation. And you can make modifications to the warehouse while the model is running. See how any changes affect the warehouse and what can optimize the model without having to restart the model.

DT Studio® supports unlimited data entry and model size, allowing for any size warehouse to be simulated within the integrated Simcad DT tool. This capability allows for comprehensive analysis and detailed simulations regardless of the volume or complexity of the data.

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The DT Studio® Difference

Digital Twin Studio® is your everyday data driven warehouse management tool, whether you're optimizing today’s picks, or planning for expansion weeks, months, or years down the road.

Slotting Optimization

Use Digital Twin Studio to connect the dots between inventory constraints, racking configuration, and cost factors that can impact efficiency.

 

Automation Integration

Want to add automation or optimize your current fleet? Test AGV, AMR, or ASRS logic in Digital Twin Studio before you invest to know you're making the right decision.

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Pick Path Analysis

Digital Twin Studio shows your warehouse heat maps, spaghetti diagrams, and congestion analysis.

 

 

New Warehouse Design

Building a new warehouse? Expanding or adding more racking? Test your layouts in Digital Twin Studio to see how different designs impact efficiency.

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Inbound & Outbound Logistics

Whether products are coming in or going out, Digital Twin Studio® smooths the entire process. From optimizing dock schedules to streamlining shipment routes, your team will experience only positive efficiencies.

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Inventory Management

Managing stock levels doesn’t have to be a guessing game. Digital Twin Studio® blends real-time data and predictive analytics to keep your inventory just right—no more, no less. A well-balanced inventory leads to satisfied customers and a healthier bottom line.

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Order Picking Optimization

Let Digital Twin Studio® learn from your warehouse to provide smarter pick paths and order releases. Year-round picking efficiency? Order fulfillment simplified? Check and check.

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Warehouse Layout Planning

Planning a warehouse redesign? Digital Twin Studio® provides the support you need to visualize new layouts, test scenarios, and optimize space utilization. From concept to reality, we help you create the warehouse of the future.

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Labor Management

Balancing workloads and schedules used to be complex and time-consuming. Digital Twin Studio® is here to forecast labor needs, optimize shift planning, and support your team—keeping everyone productive and engaged.

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Native connectivity

DT Studio® features direct connectivity to Warehouse Management Systems (WMS) and Warehouse Execution Systems (WES). This integration ensures seamless data flow and real-time synchronization between operational processes and management platforms.

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Equipment Utilization & Maintenance

Equipment downtime can throw a wrench in your operations. Digital Twin Studio® monitors equipment health and predicts maintenance needs, so you can keep things running smoothly without unexpected surprises.

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Track your KPIs

Custom Analytics allows for tailored data analysis according to specific business needs and requirements. This feature enables users to create personalized reports and insights, offering flexibility and precision in evaluating performance and making strategic decisions.

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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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