Graduation project · 2023 Walmart Global Tech · Supply chain Live & Simulator

A warehouse you can test the future on.

A digital-twin platform for Walmart's distribution centres, a live, real-time model of the building where a manager can run a "what if," see how it plays out, and validate the plan in a risk-free sandbox before it ever touches the floor.

Souporno Mukherjee, Information & UX Design · M.Des, National Institute of Design · internship & graduation project at Walmart Global Tech India

My role
Information & UXSole designer
Team
Product + EngPitched to leadership
Domain
DC operationsWalmart US
Duration
~5 monthsDouble-diamond
warehouse-twin · Live view · DC 5504
Final live view, plan overview with colour-coded zones and warehouse score
6
design iterations, V1 to final V6
2
modes, a Live view and a Simulator
1
Warehouse Score, one number to move
0
risk, every what-if runs on the twin first
01
Context

Where a warehouse sits in the world's largest retailer

Walmart runs one of the largest supply chains in the world. The distribution centre (DC) sits in the middle of it: trailers in, product slotted, orders picked, pallets out, every hour of every day.

I was placed with Walmart US, and the brief sat deep inside DC operations. Every minute of dock time, every mis-slotted pallet, every under-staffed shift costs money downstream. The recurring question was simple to ask and brutal to answer: what's the best way to run this building today?

A DC receives freight (less-than-truckload and full-truckload), holds staple stock, assembles and ships to stores. To design for it, I first had to understand how goods actually flow through it.

Freight flow: supplier to distribution centre to store
The freight flow, supplier → distribution centre → store
How a distribution centre operates, floor plan
Inside the building, receiving, sorting, staple stock and shipping lanes
02
The brief

The ask arrived as a requirements doc, and one loaded word

The product team, managers and engineers pitching this upward, wanted a platform to simulate daily DC operations and optimise the supply chain. "Simulating" meant taking today's live data and all the history, and playing a future scenario forward before committing to it.

"Build a simulation platform for daily DC operations… giving managers visibility into a scenario before it happens."
Solution proposal, from the product requirements document

Before drawing anything, I broke down the vocabulary: digital twin, simulation, Monte Carlo. If I couldn't explain those with a metaphor a warehouse manager would nod at, no interface would save the product.

03
The concept

So, what actually is a digital twin?

I explained it the way I explained it to the team: with a rocket and a chessboard.

A digital twin is a virtual replica of a physical thing, same shape, temperature, wear, kept in sync by real-time data. On the virtual side you can model, simulate, monitor and predict without risking the real one.

A chess app quietly simulates thousands of futures for every move, then picks the best one. A twin does the same with a Monte Carlo method, running many possible futures to find the best call.

Real space vs digital twin, a rocket and its data-linked replica
The mental model, real space and its data-linked twin
Digital twin for simulation, live view and simulator
The two halves that would become the product, Live view and Simulator
04
Research · going broad

The product was hiding inside everyday questions

Before drawing screens, I framed the problem. Good framing makes decisions easier and stops the scope from creeping. The platform's job showed up in the questions managers ask every shift:

01"Given a store order, how should we construct the outbound pallets?"
02"What's the logic to allocate an item to its slot?"
03"How many associates should do order-filling for an area today?"
04"How many orders should we sign up for dispatch before the shift ends?"
05"What if I add one more associate to the dock, what changes?"

Each one is a hypothesis waiting to be tested. Treating them as "questions the user wants to ask the future" defined the whole product, and later became its central interaction.

Early sketches breaking down the problem
Thinking it through on paper first
05
Benchmarking

Everyone else built for engineers. That was the opening.

I studied the market and Walmart's own tools. They were powerful and precise, and they all shared one problem: a steep learning curve meant for simulation engineers, not the people on the floor.

FlexSim warehouse simulator
FlexSim, 3D simulation modelling
AnyLogic simulation
AnyLogic, multi-domain simulation
Korber warehouse simulation
Körber, virtual warehouse models
Walmart in-house simulation platforms Cosmos and Mobius
Walmart in-house, Cosmos & Mobius
Design it so simple it needs no manual, put the power of a simulation engineer in the hands of a warehouse manager.
The inference that redirected the whole brief
06
The users

Meet Emma, who runs a warehouse with no way to test a call first

To keep the work honest I tied it to real people, and made the case the clearest way I could: the same manager, one day without the twin, one day with it.

Comic: Emma has no superpowers, slotting breaks, no slots found
01 · Without the twin, the surge hits, and the slotting doesn't hold
Comic: Emma has a digital twin, she simulates and optimises ahead of the surge
02 · With the twin, she sees the surge coming and optimises in advance
Emma Davis persona, goals, frustrations, motivations, needs
Primary persona, Emma Davis, DC / Store Manager

And Curious Jane, the explorer

Jane wasn't content to react. She wanted to experiment, to poke at five scenarios in her head and see which one wins. Today that means spreadsheets and waiting on other teams. Her frustration became the question the product had to answer:

"What if there was a way to see the future, to take objective decisions backed by data that actually improve how the warehouse runs?"

Curious Jane persona, cannot experiment with the live warehouse
Secondary persona, Curious Jane
07
Ad-hoc prototyping

Then the project lurched. Make it real, fast

An ad-hoc ask landed mid-research: show leadership what this could look like, now.

So I zoomed in. Sketching over a line-map of the warehouse, I built an outline, then added an isometric view of the building, a live viewport, and cards suggesting simulations. The first screens got a green light from higher up, and with it, room to redefine the brief and go deeper on research.

Early isometric warehouse concept screen
The isometric live viewport that got the go-ahead
08
Re-discovery & new insight

A synthesis on paper, and a keynote that validated the bet

Hand-drawn synthesis of the whole system
Everything, externalised onto one sheet

With the green light secured, I pulled the whole project onto a single synthesis map. The final shape needed three things: a live viewport, a hypothesis builder, and an outcomes page that optimises the answers.

Then Microsoft Ignite put the "industrial metaverse" on stage: digital twins for industry, exactly this area. Equinor, Mercedes and Coca-Cola were already building twins before building the real thing. Seeing that told me the bet wasn't mine alone.

The metaverse in three types: consumer, commercial, industrial
Three types, the twin lives in industrial
Equinor digital twin example
Industry, already doing it, Equinor
Azure digital twin reference interface
A reference twin, Azure
09
The final brief

One sentence set the bar for everything after

How might we
enable DC operations managers to experiment with strategies, execute and validate them in a risk-free environment, before taking high-stakes plans to production?

The platform had to be easy to pick up, cover many use cases, and offer both a live view and a simulator view. I ran the whole thing on the Design Council's double diamond, diverging to explore, converging to decide, twice.

Discover
DC, users, benchmarking
Define
personas, framing, brief
Develop
6 iterations of design
Deliver
final flow & validation
10
Design iterations

Six versions, trading clarity against completeness

The design changed a lot across versions: an isometric first bet, a dark data-dense middle, a calm and legible end. A few turning points:

Dark-mode live view exploration
Explored, a dark, data-dense live view
Warehouse score breakdown
Introduced, the Warehouse Score

Key moves across versions: splitting Live and Simulator into separate silos so daily work wasn't obstructed; a schematic plan view with colour-coded zones; the Warehouse Score to gamify optimisation; a sidebar and living design elements; and an alternate input, scan a rack with image recognition to seed a hypothesis.

Mobile AR scan to build a hypothesis
An alternate input, scan the shelf to start a simulation
11
The shipped product

Two modes: see the building, or test a change on it

Version 6 settled into two modes: a Live view to see the building at a glance, and a Simulator to try changes before making them. Step through the flow the way a manager would.

warehouse-twin · Live view
Product screen

Live view, the default screen. Colour-coded zones by temperature, trailer status, and the Warehouse Score, all in one glance.

The core interaction: write a hypothesis

The everyday questions from research become a conversational, fill-in-the-blanks sentence. Ask the future a question in plain language and the system does the rest, testing the decision before it's real. When the outcome looks good, one action pushes it to production.

Recommended items and simulations
The twin suggests, too, ranked recommendations
Success screen, optimisation applied to platforms
Apply the change once you've tested it
12
Way forward & reflection

A warehouse today. Any complex system tomorrow.

The concept doesn't stop at a loading dock. The same three parts, a live twin, a plain-language hypothesis builder, an outcomes optimiser, could work anywhere: point them at a store, a transport network, a fulfilment line, and let anyone test decisions before making them.

Measuring the process honestly, I plotted the double diamond against the pages it took to document each phase. The back half of the second diamond, iteration and refinement, took by far the most time. The planned process and the real one rarely match, and that's the lesson.

Double diamond plotted against documentation page counts
Envisioned vs actual, where the time really went
The takeaway
The platform let a manager test a decision before committing to it. Give someone a safe place to check a plan, and they'll try the ambitious version instead of the safe default. Backed by real data, that was the point of the whole project.
Souporno Mukherjee
Information & UX Designer · writinsam@gmail.com
Digital Twin for Warehouse Simulation
Walmart Global Tech India · M.Des, NID · 2023
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