Case Study: DHL Group optimizes warehouse picking with SIMUL8 simulation-powered digital twin

DHL Group improves warehouse planning with SIMUL8’s 98% accurate digital twin

DHL Group, a global logistics leader, faced challenges in optimizing staff allocation at its largest distribution center in Latin America. Manual forecasting using spreadsheets led to inefficiencies, missed daily picking targets, and customer dissatisfaction, especially during peak order periods. To address this, DHL partnered with vendor SIMUL8 and its channel partner Simulate to create a simulation-powered digital twin for operational planning.

The solution involved SIMUL8's technology to build a digital twin of the warehouse management system and a separate simulation called the 'Crystal Ball' for staffing predictions. This system provided 98% accurate forecasts for the number of pickers needed per shift. The implementation increased productivity, reduced resource shortages, improved profit margins, and enhanced customer satisfaction by ensuring timely order fulfillment.

DHL Group