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Procedia Computer Science 00 (2022) 000–000
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Procedia Computer Science 219 (2023) 370–377

CENTERIS – International Conference on ENTERprise Information Systems / ProjMAN –

International Conference on Project MANagement / HCist – International Conference on Health
and Social Care Information Systems and Technologies 2022

A Literature Review on Digital Twins in Warehouses

Marie-Jane Bélangera,*, Robert Pellerina, Samir Lamourib
a
Polytechnique Montréal, Department of Mathematics and Industrial Engineering, Montréal (Québec) H3C 3A7, Canada
b
LAMIH CNRS, Arts et Métiers ParisTech, Paris, France

Abstract

Due to the high cost of their warehousing operations, many manufacturing companies are looking to increase the efficiency of
their warehouse. To this end, Industry 4.0 technologies offer several solutions to address this issue. One of them is the digital twin
(DT) technology which is relatively new. This paper presents a literature review on DTs in warehousing. The analysis framework
used to classify the papers includes the general description of the DT, the possible uses, and the required data. Our results show
that several limitations remain to exploit the full potential of a DT. The limitations mainly concern the characterization of the data
required.
©
© 2022
2023 The Authors. Published by ELSEVIER
Elsevier B.V.B.V.
This
This is
is an
an open
open access
access article
article under
under the
the CC
CC BY-NC-ND
BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review underresponsibility
Peer-review under responsibilityofofthe
thescientific
scientific committee
committee of the
of the CENTERIS
CENTERIS – International
– International Conference
Conference on ENTERprise
on ENTERprise Information
Systems / ProjMAN
Information Systems- /International
ProjMAN - Conference
International onConference
Project MANagement
on Project /MANagement
HCist - International
/ HCistConference on Health
- International and Social
Conference on Care
Information
Health Systems
and Social andInformation
Care Technologies 2022 and Technologies 2022
Systems
Keywords: Review; Warehouse; Digital twin; Material Handling; Industry 4.0.

1. Introduction

Many manufacturing companies are looking to increase the efficiency of their warehousing process. This is mainly
due to the high cost of warehousing operations, accounting for 40% of the total production cost [1]. Warehousing
mainly consists of six operations types: receiving, storing, picking, sorting, packing, and shipping [2]. The operation

* Corresponding author.
E-mail address: marie-jane.belanger@polymtl.ca

1877-0509 © 2022 The Authors. Published by ELSEVIER B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the CENTERIS – International Conference on ENTERprise Information Systems /
ProjMAN - International Conference on Project MANagement / HCist - International Conference on Health and Social Care Information Systems
and Technologies 2022
1877-0509 © 2023 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the CENTERIS – International Conference on ENTERprise
Information Systems / ProjMAN - International Conference on Project MANagement / HCist - International Conference
on Health and Social Care Information Systems and Technologies 2022
10.1016/j.procs.2023.01.302
 Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377 371
2 Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000

that involves retrieving products from the warehouse to complete a customer order is picking. This is the most
expensive operation in the process and equates to 60-70% of warehouse costs [3]. Thus, reducing pickup time would
provide companies with a financial gain. To achieve this, the use of an inventory positioning strategy proves to be
quite useful. A proper positioning strategy can speed up product handling in the warehouse [4].
Defining an appropriate strategy for positioning inventory during storage can be complex. Several factors must be
considered, such as the size and layout of the storage system, the material handling system used, and the picking
method [5]. Obviously, this process is not optimal, hence the interest in creating an environment that will allow the
control of factors relevant to storage. Industry 4.0 technologies offer several solutions to overcome these difficulties.
Specifically, "Industry 4.0 is a strategy that relies on digital and ubiquitous connectivity, through different
technologies, to transform processes, products, and services through real-time and decentralized decision-making that
allows new capabilities to emerge for systems, in cooperation with humans, to go from monitoring to autonomy" [6].
DT (Digital Twin) technology is a relatively new Industry 4.0 concept. Briefly, a DT corresponds to a real-time virtual
representation of a physical system that assists in optimizing that system [7]. This is a high-demand research area due
to the significant potential for the manufacturing sector. Real-time monitoring, decision-making, and process
optimization and evaluation are examples of DTs' applications [8].
This paper addresses this issue by seeking how researchers had proposed to improve decision-making for
warehousing using DT technology. This literature review is divided into four parts. The first part explains the concept
of DT generically before discussing its potential uses and data requirements. Second, a literature search strategy for
DTs in storage is presented. The scientific work resulting from this strategy is then analyzed in the third part before
concluding this paper.

2. Analysis framework

2.1. General description

A DT can be defined as a complete and dynamic virtual representation of a physical system or process [9]. To
further refine this concept, Hribernik, et al. [10] identified the main components of a DT: system state (data and
representation of the actual state), system design (parameters, information, and static models), and system behavior
(models describing the behavior of their physical counterpart, analysis, simulation, and prediction). However, there is
no formal definition in the literature, which leads to confusion in the maturity of DT [11]. As represented by Fig.1,
the three maturity levels are distinguished primarily by the data flow between the physical system and the virtual
model. The digital model is a static replica of a physical system. This level is characterized by a manual data exchange
between the physical system and the virtual model. The second level is a digital shadow. The unidirectional data flow
from the physical system to the virtual model represents the exact behavior of the physical system. As for the DT, a
complete and automatic bidirectional data exchange is possible between the two entities. This implies that a change
in the physical system will cause the virtual model to change and vice versa [11].

Fig. 1. Digital model, shadow and twin (adapted from [11]).

Another property characterizing DT is the level of fidelity of the virtual model to replicate the physical entity
accurately [12]. A high level means that the physical and virtual entities are perfectly aligned, allowing for a more
accurate simulation and optimization [12]. This improves confidence in the results. To ensure a high level of fidelity,
VV&A (Verification, Validation, and Accreditation) of the model can be performed [13]. VV&A includes statistical
372 Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377
Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000 3

and dynamic methods to "analyze whether and to what extent, the accuracy, tolerance, availability, and operating
result meet the requirements" [14]. In short, model validation is critical to drawing conclusions with confidence.

2.2. Utility

The second perspective discussed of the DT is its utility. As mentioned in the introduction, a DT can be used in
various cases serving different needs. A DT is used primarily for three reasons: to run simulations, make predictions,
and/or make decisions that will impact the physical entity involved [15]. It is not necessary for a DT to simulate all
aspects of the physical system. The intended use of the DT should determine the important aspects of the physical
system to be simulated [16]. Therefore, the utility of the DT also impacts the data collection process [15].

2.3. Required data

According to the definition of a DT, several data from the physical entity, called input, must be passed to the virtual
model. Virtually replicating a physical system is usually a complex task requiring a massive amount of data [17]. The
intended use of a DT also impacts the required data. Still, the literature offers some methods to describe the required
information. In particular, Jones, et al. [12] have classified the necessary data into 10 types of input parameters (see
Table 1). Kaiblinger and Woschank [18] propose characterizing the data according to its sources (see Table 2). These
two classification methods will be used in Section 4.3 to analyze the data used in DTs for warehousing.

Table 1. Parameters classification (adapted from [12]). Table 2. Sources parameters (adapted from [18]).
Types Description Sources Description
Shape Geometric structure of the entity Historical data Stored data
Functionality Movement and/or purpose of the entity Physical space data Static attributes and dynamic condition
data
Health Actual state of the entity in relation to its ideal Provided services data Data collected during service execution
state
Location Geographic position of the entity Virtual model data Simulation results
Process Activities in which the entity is engaged Expert knowledge Domain experts
Time Time it takes to complete an activity and the Pre-processed data Data that has been cleaned, merged, and
date/time an activity takes place interpreted
Status Measured current state of all parameters of the
entity and the environment
Performance Measured operation of the entity relative to its
optimal operation
Environment Physical and virtual environment in which the
entity exists
Miscellaneous Qualitative information and generally not
qualitative measurable by traditional Internet of Things
(IoT) sensors

On the other hand, data quality represents a considerable challenge when implementing a DT. However, this factor
is crucial to its proper functioning. In concrete terms, the issues for companies are as follows: "uncertainties about
data quality and reliability; difficulty in ensuring data validity; difficulty in ensuring data governance, ownership and
management; and the impossibility of directly measuring all data relevant to the DT" [19]. Papers will be analyzed
from this perspective to support research in this direction.

3. Methodology

To obtain a current picture of the scientific knowledge on DTs in storage, a systematic literature review was
conducted in the Scopus database. This research includes the following two key concepts: DTs (technology) and
warehousing (application domain). Keywords have been identified for each of these concepts. The following query
was therefore constructed in Scopus:
 Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377 373
4 Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000

Query: TITLE-ABS-KEY-AUTH(("Digital Twin") AND (stor* OR "material handling" OR warehous*)) AND

LANGUAGE(english) AND (EXCLUDE(SUBJAREA, "ENER")) AND (EXCLUDE(SUBJAREA, "BIOC"))
Inclusion and exclusion criteria, such as language and field of application, were applied during the search to sort
the retrieved articles. Publications in the fields of energy, biochemistry, and molecular biology were excluded. Also,
only publications written in English were retained. This reduced the number of publications from 467 to 357 results
in the Scopus database. Reading the titles and abstracts allowed us to exclude 332 publications, reducing the number
of results to 25. This step made it possible to eliminate publications that did not correspond to the scope of the research.
Then, publications using the concept of digital twin only as a keyword, example of fact, or quoted expression was
excluded after the complete reading of the articles. Thus, 19 publications were selected for analysis.

4. Results

4.1. General description

Several interesting findings emerge from the selected publications. Notably, Gao, et al. [20] show that a digital
twin of an automated warehouse helps operators make optimization decisions. In addition, an order picking system is
one of the application cases that can greatly benefit from the potential of a digital twin [21].

A first general classification of the contributions was made according to the method proposed by Hofsajer [22] (see
Table 3). This author proposes a classification of the contributions into three categories (observation, model, and
recipe). Most of the publications fall into either the model category (description, graphs, etc.) or the recipe category
(algorithm, procedures, processes, etc.). Different levels of maturity are presented in the articles. In one article, a gap
is perceived between the expected and actual maturity level of the twin [1]. Publications that do not mention any
simulation model will not be analysed according to the other two perspectives of interest. Finally, only one paper
presents a model validation performed by inferential statistical analyses [23]. In general, papers focus more on
validating proposed frameworks or algorithms than on validating DTs [2, 24].

4.2. Utility

As shown in Table 4, DTs can be used for several applications at the warehouse level. For example, a DT can
ensure the safety of handling operators [25, 26], optimize inventory positioning [1, 27], and even be used to test an
algorithm for order picking [24]. It is also noted that some models are primarily aimed at simulation, and no decisions
are made [2, 23, 24, 28], while in other papers, a predictive model making decisions is presented [21, 29-31].

4.3. Required data

From a data perspective, very little information is specified regarding the inputs to the models (see Table 5). In
fact, no details are given regarding the quantity and quality of the data except for the paper by De Luca and Osello
[27]. These authors use a data-cleaning system. However, no additional details are provided in this sense. Moreover,
the synchronization is usually done in real-time. Kauke, et al. [21] are the only authors having defined a variable
update frequency depending on the data. Also, the data is mainly sourced from the physical space (PS) through the
internet of things technologies, such as sensors, smart wearables, and sensing cameras [25]. Several papers also use
simulation results (SI) as input to the DT. In terms of data types, these are mainly used to describe equipment status
(E), orders (D), products (F and FC), and their locations (L) in the warehouse.
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Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000 5

Table 3. General classification.

Goal Category Maturity Validation
[32] Optimize material handling in a cyber-physical production environment Heuristic optimization algorithm for production cell provisioning NA NA
[2] Help 3PL managers decide on the appropriate WMS customization Conceptual framework of a decision support tool for WMS customization S NS
[24] Optimize retrieval performance of metal parts in an automated warehouse Meta-heuristic algorithm based on the simulated annealing procedure that M NS
indicates from which package to take the items to complete the orders
[33] Present the results of a pilot warehouse DT Modular agent-based discrete event simulation model combined with radio- T NS
frequency identification (RFID) systems
[28] Describe the design of a logistics system using simulation and emulation Methodology for realizing the interconnection between simulation and S NS
emulation
[34] Present a warehouse management system with drones based on DT and 5G technology Conceptual architecture of an intelligent warehouse T NS
[23] Identify and validate a simulation-based decision support tool for internal logistics operations DT architecture for simulation-based internal logistics systems M
[27] Reproduce a virtual warehouse through parametric numerical modeling Virtual warehouse model for warehouse space management including mixed S NS
reality and BIM (Building Information Modeling)
[35] Describe the structural and dynamic parameters of a stacking robot Mathematical model of structural and dynamic parameters of a stacking robot NA NA
[20] Better planning of a stockyard when an uncertain scenario occurs DT-based planning framework for an automated warehouse park T NS
[29] Predict, monitor, and diagnose material flows with a DT of a material handling system Design methodology of a DT for material flow based on physical simulation T NS
[21] Support operational control in order picking systems Conceptual framework of a DT for an order picking system T NS
[1] Propose a new joint optimization approach for storage in an automated warehouse Package-location matching algorithm and packing optimization algorithm S NS
based on the overlay technique
[30] Introduce synchronization strategies in distribution centers based on the PI paradigm Inbound synchronization framework based on DTs T NS
Neuro-fuzzy inference system for order arrival prediction
[36] Increase the consideration of contextual information in DTs Graph-based contextual level model NA NA
[37] Identify an optimal strategy for simulator parameters to achieve the best resemblance to the Trained neural network to adjust DT parameters for a storage system NA NA
real storage system
[25] Present a concept and prototype of DTs to represent operators in the material handling Conceptual framework of a DT to analyze worker fatigue in handling/lifting T NS
industry operations
[31] Reduce production equipment downtime Proactive handling method for cyber-physical system equipped shops T NS
Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377

[38] Increase emergency response to incidents in refrigerated warehouses Monitoring framework based on IoT and DTs (iSafeTrack) T NS
Algorithms for detecting abnormal motionless behavior

NS = not specified, NA = not applicable. Maturity: M = Model; S = Shadow; T = Twin. Categories: Model = Dark Grey, Recipe = Light Grey, 3PL = Third Party Logistics
 Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377 375
6 Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000

Table 4. Utility of DTs.

DT goal DT utility Output
[2] Help 3PL managers decide on the Simulation The analysis of the simulation results allows identifying the best strategy for
appropriate customization of a WMS Decision support inventory positioning
[24] Test and evaluate the proposed Simulation Analysis of the simulation results allows evaluating the performance of the
algorithm algorithm
[33] Optimize routes and space allocation Decision The sequence in list form for loading and unloading materials (optimized
while trying to reduce the distance routes)
traveled
[28] Optimize material procurement for Simulation Analysis of the simulation results allows identifying the most appropriate
manufacturing configuration for the production line and the ideal configuration of the
manufacturing cycle time
[34] Reduce warehousing costs through Decision Indicates the best position of the goods in the warehouse shelves and informs
intelligent and controllable warehouse the operator if abnormal information is detected
management
[23] Test and evaluate the proposed Simulation Analysis of the simulation results shows that the models designed according
architecture to the proposed architecture accurately represent real-world operations
[27] Serve as a 3D virtual model of a Simulation Evaluate different scenarios in terms of time and cost for the identification
warehouse Decision support of storage areas
[20] Optimize the planning of the storage Decision Proposes a scheduling plan for ASCs
area, AGVs, and ASCs
[29] Control the parameters of the Prediction Indicates acceleration and speed for the fastest and safest handling.
automatic handling system to prevent Monitoring Notify the operator when a disturbance is detected
the part from falling off the pallet Decision
[21] Assist with picking decisions Prediction Indicates the possible causes of a failure that has occurred
Decision Indicates the required size of the picking round, the human resource
planning, and the order release strategy to be used
[1] Optimize the packaging and storage Decision Indicates where the packages should be stored
allocation of products in a warehouse Indicates how to palletize items
[30] Optimize joint order fulfillment and Prediction Indicates the TIS strategy to be adopted: Coordinates joint OFR operations,
replenishment operations Decision predicts order arrival, and consolidates a set of PI orders for batch
processing
[25] Reduce injuries caused by improper Decision Provides feedback to the operator on his fatigue level based on the change
manual handling movements in joint angles
[31] Proactively assign logistics tasks to Prediction Indicates an optimal combination of delivery tasks and smart carts based on
intelligent trucks, minimizing transport Decision their future status and current information
distance and energy consumption
[38] Optimize operator safety management Decision Informs supervisors if the operator is in danger

4. Conclusion

This paper presents the current state of scientific knowledge on DTs in storage analyzed from three perspectives.
The literature presents various cases of very specific applications of DTs in storage. Some weaknesses and limitations
have been identified in this review that prevent the full exploitation of a DT. One of the main weaknesses identified
is the lack of validation of the simulation model. Some authors plan to perform a validation soon [21]. However, the
accuracy of the results is directly impacted by the ability of the model to accurately represent the physical system.
Furthermore, although the data exchange between the virtual and physical model is central to the operation of a DT,
additional work must be done in this direction. It is not only a question of identifying the relevant data to be integrated
into the model but also of characterizing them in terms of quantity, quality, and precision.
In many cases, the data used are incomplete. For example, Gao, et al. [20] acknowledge that several pieces of
information that can impact the process flow, such as bad weather and road congestion, are missing from their model.
376 Marie-Jane Bélanger et al. / Procedia Computer Science 219 (2023) 370–377
Marie-Jane Bélanger et al. / Procedia Computer Science 00 (2019) 000–000 7

In addition, the integration of a knowledge base including various scenarios and their appropriate solutions is strongly
suggested by Gao, et al. [20], among others, to help operators make optimal decisions.

Table 5. Data’s information.

Sources Types
Quantity Quality Synchronization
H PS S SI K P F FC H L PR T S P E M
[2] NS NS NS X X X X X X
[24] NS NS Static X X X X
[33] NS NS 30 minutes X X X X X
[28] NS NS Real-time X X
[34] NS NS Real-time X X X X X
[23] NS NS Static X X X X
[27] High Data cleaning Real-time X X X X X X
system
[20] NS NS Real-time X X X X X X X X
[29] NS NS Real-time X X X X X X
[21] High NS Varies according X X X X X
to the data
[1] NS NS Periodic X X X X X X X
[30] NS NS Real-time X X X X X
Consolidation:
60 minutes
[25] High NS Real-time X X X X X
[31] NS NS Real-time X X X X X X X
[38] NS NS Real-time X X X
NS = not specified. Source: H = Historical, PS = Physical space, S = Services provided, SI = Simulation, K = Expert knowledge,
P = Preprocessed. Type: F = Form, FC = Functionality, H = Health, L = Location, PR = Process, T = Time, S = State, P = Performance,
E = Environment, M = Miscellaneous qualitative

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