Customer Case Study · Supply Chain · Plant Logistics
A 3D logistics digital twin of a room-AC plant. It follows every supplier truck from the gate to the dock, every packed lot from the final line to the dispatch yard, and lets the plant test peak-season what-ifs before a single truck queues.
Figures indicative; validated metrics available on request.
In AC season (January to April) inbound steel, copper tubes, compressors and electronics roughly double, while the plant ships thousands of AC units a day to brand customers. All of it moves through one inward gate, six docks and one finished-goods yard.
Supplier trucks waited outside for hours while two of six docks sat idle. Security could see the queue, stores could see the docks, nobody saw both.
Gate pass, weighbridge slip, GRN and dispatch register each lived in a different book or WhatsApp group. Finding one truck took a round of phone calls.
Loaded trucks for brand customers waited for documents, seal checks and transporters. The yard filled up and detention charges climbed every peak season.
Three shifts, verbal handovers. A dock blocked for GRN at 13:50 was still blocked at 15:00, and the next shift found out when a truck could not dock.
Built with the plant's security, stores, PPC and dispatch teams, starting from their own gate registers, weighbridge slips and GRN timestamps.
Select a step to see what happened.
We followed trucks from the highway to the dock and from the line to Gate 2.
Deliverable: Truck-visit anatomy and a site layout model.
Zones, docks, bays and the rules that move trucks between them.
Deliverable: Twin specification and KPI tree.
A 3D model of the whole plant with an event engine underneath.
Deliverable: Plant logistics twin (single HTML) and what-if simulator.
The twin went on screens at security, stores and the dispatch office.
Deliverable: Control-room routine and shift-brief template.
From simulated flows to live data, plant by plant.
Deliverable: Data-feed roadmap and multi-plant template.
The twin itself is embedded below and running. Take the guided tour, switch to a peak-season scenario, then use the simulator to decide how many docks the season really needs.
Drag to pan, scroll to zoom, click any truck or building. The twin runs one plant minute per second; use the controls inside it to speed up, switch to night or show truck paths.
Pick a stop to fly the camera there, or play the whole tour.
The twin runs a simulated day. Supplier descriptions, truck IDs, destinations and volumes are illustrative; in production, events come from gate, weighbridge and ERP feeds.
At every shift change the twin's numbers and event log are turned into a one-page brief with the actions for the next shift. Press the button to draft one from the twin running above.
Queue above 3, dock blocked, yard above 70% or turnaround above 2 h each trigger a specific action for the next shift.
Rule-based sample built from the twin's live numbers. In production Claude drafts it from the full event log.
Press “Draft shift brief” to generate a handover from the twin's current state.
Simulate a full day of inbound trucks, twice: the old way (paper registers, peaky arrivals, manual dock calls) and with the twin (automatic allocation, slot-booked arrivals). Every block on the board below is one truck at a dock.
Indicative discrete-event simulation. "Before" assumes peaky arrivals, 15 min at the gate and manual dock calls; "with the twin" assumes slot-booked arrivals, pre-registered trucks and automatic allocation. The live version is calibrated on the plant's own visit data. Detention is estimated at ₹250 per truck-hour beyond 3 hours, 26 working days a month.
Unloading time hardly changed. What disappeared was the waiting around it: in the parking yard, on GRN holds and for documents in the FG yard.
Average minutes per step, peak season
Average trucks waiting at gate and yard, by hour and weekday
Figures indicative; validated metrics available on request.
Most of a truck's visit was invisible waiting, not slow unloading. Putting every truck on one screen cut it before any new dock was built.
Running peak arrivals through the simulator showed when a seventh dock pays back and when slot booking alone is enough.
An auto-drafted shift brief kept context across three shifts and gave the plant head one page every morning.