Project Overview

A large distribution center faced frequent flow imbalances and unplanned congestion in high-traffic zones. Managers lacked visibility into live operations and decision-making relied heavily on experience rather than data.

Problem Statement

Manual tracking and static layouts made it difficult to identify bottlenecks or test improvements. Planners couldn’t predict the impact of layout changes, workforce adjustments, or new product introductions.

Solution

We built a digital twin of the warehouse using live data inputs from scanners, forklifts, and WMS logs. This model allowed simulation of various scenarios, such as route adjustments, staffing changes, and new layout proposals without disrupting operations.

Result

• 32% reduction in unplanned waiting and traffic conflicts.

• Informed data-driven layout and labour decisions.

• Created a permanent digital platform for continuous improvement and future automation planning.