Digital Twin & Simulation Service - Business Capabilities

Service Overview: The Digital Twin & Simulation Service creates a virtual replica of warehouse operations for scenario testing, capacity planning, layout optimization, and predictive analytics using real-time data synchronization and discrete event simulation.

Architecture: Event-Driven Architecture with Simulation Engine Technology Stack: Spring Boot 3.2, PostgreSQL, TimescaleDB, Redis, Apache Kafka, AnyLogic/SimPy Domain Model: State synchronization with simulation modeling framework

L1: Predictive Operations Intelligence

L1.1: Strategic Value

• Risk Mitigation: Test changes before implementation with zero operational risk
• Optimization: 15-20% throughput improvement via simulation insights
• Planning Accuracy: 95%+ accuracy in capacity projections
• Innovation: Rapid prototyping of new operational strategies

L2: Core Capabilities

L2.1: Digital Twin Synchronization

• Real-time state mirroring of physical warehouse
• Bi-directional data sync (actual vs. simulated)
• High-fidelity 3D visualization
• Historical replay and time-travel debugging

L2.2: What-If Scenario Analysis

• Layout reconfiguration simulation
• Peak season capacity modeling
• Equipment investment ROI analysis
• Process change impact assessment

L2.3: Discrete Event Simulation

• Order flow simulation with statistical distributions
• Resource contention modeling
• Bottleneck identification
• Multi-variable optimization

L2.4: Predictive Analytics

• Throughput forecasting under various conditions
• Equipment utilization prediction
• Labor requirement projections
• Service level impact modeling

Key Metrics

• Simulation accuracy: 95%+
• Real-time sync latency: < 2 seconds
• Scenario execution time: 5-30 minutes
• Model complexity: 500+ entities

Performance Targets

• State update processing: < 500ms
• Scenario initialization: < 10 seconds
• Visualization rendering: 60 FPS
• System availability: 99.5%