Transparency in the Warehouse Through a Digital Twin

Targeted improvement measures to boost warehouse performance at the central logistics center

The uvex group is an internationally active manufacturer of protective and safety products for work, sports, and leisure. The company operates its central logistics center—featuring an automated high-bay warehouse and an automated small-parts warehouse—at its Rednitzhembach site. As part of the site consolidation and the ramp-up of the new logistics center, performance fluctuations occurred in the operational warehouse processes. Performance had already improved noticeably, but the necessary transparency regarding the specific influencing factors was still lacking. In this project, Rothbaum Consulting established transparency regarding the key drivers of warehouse performance and created a prioritized foundation for targeted measures. The strategic and operational EWM app enables uvex to track the impact of these measures in day-to-day operations and to continuously improve warehouse management.

Portrait of Thomas Heinicke, Director of Group Logistics / CEO of uvex Group Logistics GmbH UVEX GROUP Logistics GmbH

With Rothbaum Consulting, we have used data to visualize the operational interrelationships at our new logistics center. The clear action items and dashboards provide us with a solid foundation for further stabilizing and sustainably improving our warehouse performance in a targeted manner.
Thomas Heinicke, Director of Group Logistics / CEO of uvex Group Logistics GmbH, UVEX GROUP Logistics GmbH

From Unclear Correlations to Specific Influencing Factors

Challenge

After consolidating several warehouse locations in Rednitzhembach, the new logistics center failed to achieve the desired throughput. Uvex lacked the transparency needed to understand the impact of order structures, process variations, and control parameters, making it impossible to identify targeted measures to stabilize operational performance.

Implementation

Rothbaum Consulting created a digital process twin in Celonis based on the Rothbaum SAP EWM app and supplemented it with targeted optimization workshops. This made it possible to identify influencing factors, evaluate and prioritize weaknesses based on data, and translate them into concrete actions.

Results

The digital twin and the Rothbaum EWM app provided transparency into actual process flows and influencing factors. This enabled the identification of 15 areas for improvement, which were then translated into concrete actions. At the same time, the EWM apps provide uvex with a central platform for monitoring over 20 warehouse KPIs and directly evaluating the impact of the measures.

60 million

Analyzed warehouse tasks

Digital Twin

Analyzed warehouse tasks

15

specific measures

Two EWM Apps for Strategic and Operational Transparency

Strategic Dashboard

Consolidates all relevant information and key metrics for management.

Operational Dashboard

Provides operational departments with the relevant information for the day-to-day management of warehouse processes.

Laptop screen displaying the uvex Operatives EWM Dashboard, which shows various bar and column charts as well as numerical values providing an overview of performance

Detailed Results

Using the digital process twin, real-world warehouse processes were analyzed based on data, and operational factors were made transparent.
Thanks to the Rothbaum SAP EWM app and Celonis, 15 pain points were identified through confirmatory and exploratory data analyses.
For each weak point, specific, coordinated measures were derived for operational, process-related, and system-level optimizations.
Strategic EWM app for comprehensive management of key warehouse KPIs.
Operational EWM app for transparency regarding process flows, weaknesses, and the impact of implemented measures on day-to-day operations.
Clear recommendations for the sequential implementation of prioritized measures.
Guidance on the implementation and effective use of the dashboards.

rothbaum-consulting-success-story-uvex-digital-twin-warehouse-english

Portrait of Clemens Wolf, a manager at Rothbaum.

Dr. Clemens Wolf

Senior Manager, Digital Operations

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