Legacy systems earned that distinction for good reason. For years, they’ve helped the companies that use them stand up, standardise and sustain operations. Unfortunately, these resources aren’t designed to last forever. According to one study, almost 90% of businesses experienced slowed-down operations due to their legacy systems.
For an industry like warehousing, where efficiency is a top-shelf priority, technology that isn’t delivering on time (or earlier) is costly — monetarily and otherwise. Next-generation solutions that enable legacy setups to analyse, forecast and deliver as fast (or faster) will define how the warehouse management landscape evolves.
Few solutions show more potential to aid in that modernisation than digital twins. Leveraging machine learning (ML), artificial intelligence (AI) and the Internet of Things (IoT), digital twins build high-quality simulations that can be used to gather insights or even simulate potential scenarios.
For leaders, this technology also enables them to empower their teams to integrate digital twins into their legacy warehouse oversight systems, allowing them to stay ahead of the curve and make informed decisions that benefit their unique business models.
How digital twins can amplify legacy system operations
Digital twins afford warehouse decision-makers a 360-degree perspective on the challenges facing their floors. In many ways, they act as a kind of virtual chalkboard that allows leaders to determine where the technology and the legacy solution can best complement one another.
Twins maximise the value they provide legacy hardware when supporting:
- Real-time monitoring and optimisation: Almost one-third of warehouse companies surveyed want to broaden the scope of their analytics solutions. Of that segment, 17% want real-time data processing incorporated into their organisations. Digital twins are living, breathing entities powered by information and capable of supporting warehouse oversight and overhaul.
Warehouses that need to test a machine’s efficacy can do so without disrupting ongoing workflow. Additionally, twins’ virtual renderings spotlight opportunity areas for improvement and provide the insights needed to make that decision. With data flowing through digital twins, the opportunity to act accurately and quickly is an alluring one for warehouse leadership. - Predictive maintenance: According to one report, maintenance-related costs can account for close to 40% of a warehouse’s expenses. When warehouse upkeep costs begin to snowball, it usually occurs due to lack of visibility or awareness of a potential issue. With a digital twin, warehouses can be proactive about potential maintenance needs of all sizes.
Digital twins can be calibrated to alert teams when a maintenance need is upcoming or past the recommended date. This can be an update as simple as a belt or screw replacement or something as broad as future compliance deadlines. In either event, proactive repairs are less costly than reactive ones – according to one study, preventative repairs can reduce maintenance costs by 18-30%. - Operational efficiency: Delays are nothing new for businesses operators worldwide. The key is knowing how to forecast them and potentially navigate the resulting disruptions, something digital twins can prove to be a valuable solution in executing.
Twins’ ability to simulate large structures to scale presents significant value to any production process. Rather than the team having to divide its attention, a digital twin can operate on its own, enabling team members to keep critical, smaller-scale production elements ongoing without sacrificing big-picture elements.
How digital twins and legacy software can complement one another
Legacy and digital twins represent two sides of the same coin. Though their compositions (cloud software and traditional hardware, respectively) are diametrically different, their intents are similar: to streamline warehouse operations. Ensuring the two are coordinated and calibrated for success requires the following:
Thorough planning
Investing in digital twin technology is a long-term investment in a warehousing provider’s viability. But it can present a paradigm-shifting change to a company’s IT philosophy, one that needs to be considered from every angle before making a final decision.
This staged approach helps manage risk, deliver early ROI, and build organizational familiarity and capability with the technology. Here’s how you can structure the implementation:
- Level 1: Connected Twin: This level aims to establish a foundation for data visualisation and live status monitoring using data integration and regular training.
- Level 2: Intelligent Twin: Here, the twin is enhanced via analytical modelling and simulation capabilities. Implementation includes advanced analytics, scenario planning, optimisation and training to enable real-time iteration and implementation via digital properties.
- Level 3: Autonomous Twin: The goal of autonomous is to prompt proactive execution capabilities via insights derived from the twin.
- Level 4: Clustered Twin: These coordinate and integrate multiple twins through network integration, communication, centralised management, planning and training.
A strategic approach to a legacy/digital twin collaboration ensures innovation stays aligned with high-level business objectives.
Strong data foundation
Data plays a pivotal role for any warehouse trying to incorporate digital twins into their legacy solution setup. Quite simply, data provides a glimpse into the how and why of these setups and can speak to how seamless the project has been or can be.
With a reliable data strategy, companies can trust that their technology foundations are built on transparent information. Further, it can shine a spotlight on the company’s overall compliance and highlights what can be done to improve matters via:
- Real-time data and monitoring: Twins work in real time, providing instant access to up-to-date information instantly (via alerts and push notifications), leading to better, quicker decision-making than legacy.
- Remote access and mobility: Unlike legacy systems, twins can be accessed from any device with an internet connection, allowing for remote monitoring and control.
- Enhanced user interface and experience: Twins update legacy systems’ less-intuitive user interfaces with modern setups that make learning to and interacting with it much easier.
- Integration with modern technologies: Twins can more easily integrate with modern solutions, improving interoperability and collaboration and allowing companies to scale the technology with new business goals without disruption.
The right technology partners
Technology is the bedrock of a digital twins and legacy technology. So why not pursue every avenue possible to ensure the tools carrying out these initiatives are top-notch and reliable for years to come?
Peace of mind can come in the form of an experienced technology services provider who is aligned with your business goals and acts as another arm of your company. This partner should not only set your warehouse up with the right kind of technology, but it should also oversee the legacy technology integration to ensure the hardware and digital twins are on the same page.
Education and change management
Introducing digital twins into legacy technology requires a bevy of front-end preparation. But once the technology is in place, that doesn’t mean the work stops; it’s critical to continue educating staff about the power of these technologies and how they’re best deployed.
Keep in regular contact with teams about new features and what expectations there are for individuals, departments and the entire company. Learn how team members are using the technology, then tailor the solution to those experiences to maximise their impact. Digital twins introduce a level of flexibility into legacy operations that some might not be used to experiencing. Communicate those changes to see this union truly thrive.
Legacy hardware still plays a critical role in modern warehouse operations. Allowing it to work in conjunction with next-generation digital twin technology can help extend its shelf life and unlock new levels of efficiency within the organisation.
Digital twins promise to overhaul the warehouse operation landscape in the short- and long-term. Our yet-to-be-released e-book, "Maximise Warehouse Efficiency and Simulate Success With Digital Twins," will explore the topic in more depth. Check back in for more details about signing up to download it.