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From Simulation to AI Orchestration. One Digital Twin Platform.

With Digital Twin Studio^®, you get the whole picture: interactive 3D models, total data visibility, and real-time optimization working side-by-side to bring your operations to life.

With Simcad^® Simulation Software you can analyze and optimize your operation using customizable, AI driven, interactive simulation engine in 2D/3D and VR.

Discover Digital Twin Studio^® → Get a Demo

Proudly serving global industries for over 30 years

How It Works

The path from simulation to live orchestration.

Simulation

Test before you commit.

Simulate, Analyze, Optimize. Run what-if scenarios on your real operational data — layouts, slotting, automation sizing, labor plans — not textbook distributions. AI explores the options and generates the configurations worth committing to, before you spend a dollar or a day.

Emulation

From behavior to control logic.

Bring your actual software stack into the loop — ERP, SAP, WMS, WCS, PLCs, RFID and fleet managers — so the digital twin runs exactly like your operation will. AI validates each decision against the systems that will execute it, for a level of fidelity simulation alone can't reach.

Monitoring Real-Time

Live visibility, every shift.

Unlock real-time operational visibility from any browser. Visualize your workflow instantly with live metrics, heatmaps, spaghetti diagrams, and congestion analysis. Easily click through to explore deep analytics and granular details. Connect your digital twin to live data to see your operation in action, from anywhere in 2D and 3D.

Orchestration Real-Time

Let the twin run the floor.

Close the loop. backed by predictive AI, the platform flags anomalies and bottlenecks before they cost you—integrating seamlessly without replacing your existing infrastructure. AI issues prescriptive work assignments, reroutes dynamically, and acts on disruption in real time — orchestration that protects your throughput before the numbers ever move.

Case Study · 3PL / Reverse Logistics

For me, it's a no-brainer. You're taking the guesswork out and replacing it with science. Our clients love it because they can see exactly how their operations will run before moving in. We're rolling it out network-wide.”

— Bob Duron, President & COO, nGROUP Performance Partners

Read the full case study →

+40%

New customer time-to-stage reduction

+50%

Lead time reduction with AI-driven slotting

Solutions

From the DC to the plant floor.

Distribution and Supply Chain

For Greenfield, Brownfield, Last Mile,
and Global Supply Chain

Analyze and optimize your design using AI-driven scenario analysis — on your actual order data, not a vendor's marketing model.
Validate the next AS/RS, AMR, or conveyor system for real-world capacity and throughput before you commit a dollar or a day.
Slotting and pick-face redesign, pick path, put-away, staging, and replenishment optimization.
Model multiple DCs, last-mile deliveries, and hub-and-spoke concepts
simultaneously.
Find the right DC footprint for your network — and minimize cost before breaking ground.

Warehouse Simulation Warehouse Digital Twin

Manufacturing

Manufacturing Line Analysis, Automation, and High-Mix/High-Volume Operations

Production scheduling that talks to SAP and the shop floor — and stays accurate when priorities shift.
Cycle time, OEE, and first-pass yield — analyzed on actual data, not statistical sketches of it.
Capital equipment evaluation before you commit — model new presses, lines, or cells against current production.
Mixed continuous-flow and discrete-event modeling in one engine — no rebuilding for each project.
Validate automation investments — robots, AGVs, and assembly cells — on your actual product mix, not vendor benchmarks.

Manufacturing Simulation Manufacturing Digital Twin

How we work with you

Get up and running in weeks, not months or years.

With over 30 years of experience and next-generation platform architecture, our team can deploy Digital Twin Studio^® in as little as 6 weeks. We'll work with your team, connect to your data sources, build and validate your model, and train your team to perform ongoing analysis and optimization.

See how easy it is →

3900+

ACTIVE DEPLOYMENTS
WORLDWIDE

6 weeks

AVERAGE MODEL
TURNAROUND TIME

10%

BASELINE OPERATIONAL
EFFICIENCY IMPROVEMENT

90 day

COMPLETE ROI

The software is super powerful for data exchange and analysis. It thoroughly reveals the pattern behind our warehouse operation. You can easily compare solutions and make a decision based on KPIs you care about most. It’s an excellent product for continuous innovation.

Ziping X.

Warehouse Solutions Engineer

Digital Twin Studio is easy to use, coding is optional, and it has an abundance of analysis tools to extract data and identify issues. The software has incredible value and functionality compared to other tools which are grueling to program, cumbersome to use, and expensive to train on.

Jason S.

Industrial Engineer

We have really enjoyed working with the CreateASoft staff, and have used Digital Twin Studio for multiple layout optimization projects—with more in the queue. The software is easy to use and very well supported. The CreateASoft staff are knowledgeable, supportive, and friendly.

Caitlin S.

Senior Planning Analyst

Thirty years of simulation. Now powering every stage of the operation.

Most discrete-event simulation engines were built to do one thing — model the operation offline. The Simcad^® engine is built to carry your model further. It's the same engine that's powered our customers' simulation for three decades — and it's the engine that now also powers AI-driven emulation, real-time monitoring, and live orchestration. One engine. One model. Every stage of the operation.

Legacy DES Engines

Simulation, and not much more.

Simulation Emulation Monitoring Orchestration

Single-threaded engines built for an earlier era of offline planning.
Statistical sampling and distributions — works for what-ifs, limited beyond.
The work stops when the model is built. No bridge to live operations.

Just need simulation? Simcad^® Pro is our standalone simulation product — powered by the same Simcad^® engine, sized for smaller-scope projects.

The Simcad^® Engine

Built to carry your model the rest of the way.

Simulation Emulation Monitoring Orchestration

64-bit, multi-threaded — built for the scale and complexity of real operations.
Neural networks trained on your actual operational data, not statistical sketches of it.
Native live integration with WMS, ERP, MES, SCADA, PLC, RFID, and labor systems.
The same engine from your planning desk to your live floor.

The full data-connected platform. Digital Twin Studio^® is what we're talking about.

See the Digital Twin Studio Difference →

CASE STUDIES

real-time S&OP Analysis - AI Digital Twin

Our patented Digital Twin Studio® replays your entire operation continuously — testing scheduling scenarios, equipment configuations, and demand shifts in minutes, not months. The result: lower cost per unit, higher throughput, less WIP.

DC Slotting & Optimization - AI Digital Twin

Our patented Digital Twin Studio® replays your live WMS data continuously — testing slotting, pick paths, and dock scheduling in minutes, not months. The result: fewer replenishment cycles, lower outbound congestion, faster dock-to-ship.

Our patented Digital Twin Studio® replays an entire transport network continuously, testing dispatch placement, and weather scenarios. The result: faster transfers, smarter dispatch, and capital decisions made on evidence — not assumption.

nGroup runs a high-complexity, multi-client reverse logistics facility in Lebanon, TN. With a constantly rotating client roster and demanding onboarding expectations, they needed to eliminate layout risk, and validate slotting decisions.