Tetra Pak chooses DHL Supply Chain for digital twin warehouse

This is the first smart warehouse for DHL in Asia Pacific to deploy the digital twin technology, which involves using digital models to better understand and manage physical assets.

Combining the Internet of Things (IoT) technology with data analytics, DHL Supply Chain created a smart warehouse solution (video) for Tetra Pak by bridging its physical warehouse with a unique virtual representation that monitors and simulates both the physical state and behavior of the warehouse assets in real time. With this digital twin solution, Tetra Pak is able to maintain 24/7 coordination of its operations to resolve issues as they occur, particularly those that involve safety and productivity. 

Warehouse supervisors can use real-time operational data to make informed decisions to reduce congestion, improve resource planning and allocate workload. Using IoT and proximity sensors on Materials Handling Equipment (MHE), spatial awareness is enhanced, thus reducing potential collision risks. Controlled areas with restricted access are also monitored with management alerts. 

A DHL control tower monitors the flow of inbound and outbound goods to maintain time efficiency, ensuring goods are correctly shelved within 30 minutes of receipt, and delivery-bound goods are ready for shipment within 95 minutes. 

To reduce operational risks and improve safety, DHL Supply Chain has implemented a container storage management solution that minimises the need for employees to handle heavy containers. All employees are also trained to work within newly introduced safety measures.