A digital twin of your warehouse floor — with live picker tracking, heatmaps, and AI-powered relocation suggestions that cut walking distances by up to 30%.
Build a complete digital replica of your warehouse floor plan. Every zone, every aisle, every shelf location — mapped and visualized in a top-down 2D view. The digital twin mirrors your physical layout with precision, showing all storage zones (A, B, C), packing stations, inbound areas, and shipping docks.
Changes to your layout are reflected instantly — add a new zone, rearrange shelving, or reconfigure pick paths, and the digital twin updates in real time. This isn't a static floor plan. It's a living, breathing model of your warehouse operations.
The heatmap overlay transforms raw movement data into actionable insights. High-traffic areas glow red, medium yellow, low green. Instantly identify bottlenecks: is aisle B2 always congested? Are pickers constantly walking to Zone C for one high-frequency SKU?
Toggle between real-time and historical views to understand patterns over time. Compare shifts, days, or weeks. The data reveals what your eyes can't see on a busy warehouse floor.
The AI analyzes picking patterns, order frequency, and walking distances to generate relocation suggestions. If SKU-4821 is picked 200 times per day but stored in Zone C's far corner, the AI suggests moving it to Zone A — closer to the packing station, reducing walking time.
Every suggestion comes with projected impact data: time saved per day, distance reduced, picks affected. Approve with one click, and the system updates all location references automatically. Over time, the AI continuously optimizes your warehouse layout based on changing demand patterns.
For multi-item orders, the system calculates the optimal route through the warehouse. The picker sees the path on their mobile device, and managers can watch it unfold on the digital twin in real time.
Compare the AI-optimized route against the manual route to quantify the improvement. Our customers typically see 30-40% shorter walking distances after enabling route optimization — translating directly into higher throughput and lower labor costs per order.
When multiple pickers converge in the same aisle, the system detects congestion in real time and alerts managers immediately. A notification appears with the exact location, number of pickers affected, and estimated wait time.
Beyond real-time alerts, the system identifies recurring congestion patterns and suggests layout changes — like widening a high-traffic aisle or adding a second pick face for popular SKUs. Prevention is always cheaper than reaction.
Discover how the Dynaflow Digitale Tweeling gives you real-time visibility into every corner of your warehouse — from picker movements to AI-driven layout optimization.