A digital twin is the final step in making warehouses ‘intelligent’

Warehouses are the unsung heroes of the supply chain. When they perform at an optimal level, they play a critical, if often underappreciated, role in ensuring the availability and timely delivery of goods.

 

Yet many remain places of disorder, where thousands of products are stacked on high shelves and workers spend hours locating and retrieving them. This is the reality for warehouses that have not yet harnessed the power of advanced technology.

 

Over the past decade, a quiet revolution has taken place in warehouse operations. The use of AI, advanced data analytics and autonomous robots is transforming performance. Businesses that have deployed these technologies have seen measurable improvements in speed, efficiency, storage capacity, stock management and waste reduction.

 

Warehouses that were once defined by complexity and inefficiency are, quite simply, becoming “intelligent”.

 

Deploying the robots

 

Today’s customers expect speed and accuracy. Every link in the supply chain must operate at peak performance, and goods must move faster than ever.

 

The warehouse sits at the centre of this challenge. Warehouses are under increasing pressure to handle higher volumes, more frequent orders and greater product diversity while maintaining accuracy. Even small errors in stock data or location can ripple through the supply chain, causing delays and higher costs.

 

When warehouse records and reality drift apart, teams waste hours hunting for stock or correcting orders. Traditionally, accuracy checks relied on manual counts or audits that were slow and easily out-of-date. Intelligent warehouse systems are transforming this process.

 

Autonomous robots can now scan aisles, pallets and racks to capture a live, precise view of inventory and space utilisation. Misplaced goods or stock discrepancies are identified instantly, allowing faster fulfilment, higher accuracy and better use of space across every shift.

 

But intelligence brings a new challenge of its own: vast amounts of data. Without the ability to interpret and act on it, valuable insights risk being lost.

 

A digital twin for warehouses

 

Dexory has developed a unique solution to this challenge. DexoryView transforms warehouse data into a living, interactive digital twin, giving businesses real-time visibility of inventory and operations at an unprecedented scale.

 

“Warehouses have long struggled with poor visibility, manual data capture, and outdated inventory information that slows operations and drives up costs,” says Oana Jinga, Chief Commercial & Product Officer & Co-Founder, Dexory.

 

“DexoryView was created to solve these challenges by providing real-time insight through autonomous data collection and digital twin technology, helping teams make faster, more accurate decisions.”

 

Digital twins help address some of the industry’s most persistent challenges, from inventory counting and error prevention to recovering misplaced stock and optimising available space.

 

Crucially, DexoryView integrates seamlessly with existing systems and requires minimal disruption to deploy. Set-up takes days rather than months, and customers typically recover their investment within just two months through efficiency gains alone.

 

“Customers using DexoryView are seeing significant efficiency and cost gains, with some achieving over 200 percent ROI in under six months,” Jinga says. “By automating stock checks and improving accuracy, businesses are saving tens of thousands of pounds annually and freeing up hundreds of hours of manual work.”

 

Proactive, not reactive

 

The shift to intelligent warehouses saves countless hours previously spent problem-solving. By deploying DexoryView, problems are spotted and addressed ahead of time.

 

Importantly, Dexoryview does not replace people; it empowers them. By removing repetitive, manual tasks, warehouse teams can develop skills in other areas and focus on higher-value activities such as analysis, process improvement and innovation.

 

Dexory’s digital twin technology is a pivotal step towards the adaptive, autonomous warehouse. It gives businesses the confidence to operate with speed, precision and resilience in an environment of constant change.

---

Learn more about DexoryView