Fraunhofer Institute for Material Flow and Logistics IML
Fraunhofer Institute for Material Flow and Logistics IML

Application examples and best practices for digital twins in logistics

How digital twins are revolutionizing logistics

Digital twins offer companies the opportunity to map logistics processes realistically in a virtual environment. By linking real-time data, artificial intelligence and IoT technologies, logistics processes can be monitored, simulated and optimized. This allows bottlenecks to be identified at an early stage, processes to be designed more efficiently and costs to be significantly reduced.

From the optimization of warehousing and the intelligent control of transport processes to the simulation of complete supply chains - digital twins offer numerous application possibilities in modern logistics.

Application examples for digital twins in logistics

  • Warehouse optimization
    Digital twins allow warehouse structures to be analyzed and optimized. Sensors record inventory data in real time, enabling optimal use of warehouse capacity and automated replenishment processes.
  • Simulation and planning of transport routes 
    Digital twins enable the analysis and optimization of routes, considering current traffic situations, weather conditions and delivery priorities. This reduces transportation times and cuts costs.
  • Simulation and visualization of interlocks 
    By connecting sensors, digital twins enable predictive planning of maintenance intervals. A comprehensive overview is ensured by mapping locks and the results of sensor inspections, e.g. of the lock gates, as well as recording the specifics of a lock.
  • Fleet management and maintenance 
    Continuous monitoring of vehicle data enables maintenance requirements to be identified at an early stage. Predictive maintenance extends the service life of the fleet and reduces unplanned breakdowns.
  • Optimization of picking processes 
    In warehouse logistics, digital twins improve route planning for order pickers and automated systems. Simulations can be used to determine the best process for efficient order processing.
  • Supply chain management 
    Companies can use digital twins to simulate and optimize their entire supply chain. Risks such as delays or material bottlenecks are identified at an early stage, ensuring better planning and resilience in the supply chain.

Best practices for the successful use of digital twins

  • Ensuring data quality
    The effectiveness of a digital twin depends on the quality and timeliness of the data collected. Reliable sensor technology and a robust data infrastructure are crucial.
  • Step-by-step implementation 
    Digital twins should first be introduced in individual areas before scaling up to complex logistics networks.
  • Integration into existing systems 
    The connection to ERP, WMS and TMS systems enables seamless use and prevents isolated solutions.
  • Real-time analysis and predictive planning 
    By using artificial intelligence and predictive analytics, digital twins can not only map current conditions but also forecast future developments.
  • Regular optimization and adaptation 
    Digital twins should be continuously developed and adapted to changing conditions in order to achieve maximum efficiency gains in the long term.

Optimize your operations by mapping your physical processes with digital twins

Digital twins enable data-driven control and optimization of logistics processes. The targeted use of this technology can significantly increase efficiency, transparency and sustainability.

Take advantage of the digital twin now!

 

 

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