Digital twins bring logistics operations to life

Logistics companies today collect more operational data than ever before. Sensors, WMS systems, tracking devices and IoT applications continuously generate information about goods flows, warehouse processes and transport movements. Yet for many companies, this data remains an underutilised resource. The methodologies, architectures and tools needed to convert this data into a digital representation of their own processes – a digital twin – are often lacking. As a result, it is difficult for logistics operators to monitor, analyse and optimise their operations virtually.

The need for a practical and scalable framework

There is a clear need for a practical and scalable framework for the development of digital twins in the logistics sector. Such a framework must enable data from diverse sources to be integrated and utilised for visualisation, process analysis, simulation and decision-making support, both within warehouses and yards and in road transport. Without such a framework, many companies continue to muddle through with isolated dashboards and data silos, without gaining a true insight into their operational reality, let alone the ability to test and adjust it virtually.

From a basic framework to a practical toolbox

As part of the COOCK+ project START2TWIN, Flanders Make and its partners worked on the step-by-step development and validation of digital twins for logistics applications.

In the initial phase, a basic framework was developed in which existing digital twin technologies, use cases, maturity levels, preconditions and integration options were systematically mapped out. Based on this, the project team developed a concrete toolbox: a practical step-by-step plan with guidelines to help companies implement digital twins and assess the data and infrastructure required to do so.

Tested in three real-world environments

This approach was then put to the test in practice through three Proof-of-Concepts in representative logistics environments:

• Two PoCs investigated the capabilities of various digital twin providers within a warehouse environment, with a specific focus on slotting strategies, order-picker routing, process improvements and layout adjustments.
• A third PoC focused on the integration of real-time data into the digital twin, and investigated the added value that these real-time data streams offer in terms of model accuracy, situational awareness and additional functionalities.

Based on the results of these pilot projects, an assessment was carried out to determine how digital twins can contribute in practical terms to the more efficient management and optimisation of logistics operations.

Practical guidance for the industry

This research project provides logistics companies with practical guidance:

• A clear overview of existing digital twin technologies and their potential applications, so that companies do not have to start from scratch.
• A practical toolbox with a step-by-step plan to help them determine which digital twin approach suits their level of maturity, data and infrastructure.
• Practical insights, gained through the three PoCs, into the added value of digital twins for slotting, order picker routing, process improvements, layout adjustments and real-time data usage.
• A well-founded basis for developing an internal business case for digital twin implementation, with a clear understanding of both the benefits and the requirements.

In short: companies wishing to get started with digital twins, or to further develop their existing initiatives, will find that START2TWIN provides them with a practical roadmap, based on real-world test cases from warehouse and transport environments.