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Digital Warehouse

A technology package for maximum performance in stock keeping and logistics

What is a Digital Warehouse?

DIGITAL WAREHOUSE stands for a technology package that ensures material flow monitoring and inventory management for steel producers and mining companies.

The system allows to make corrections, add logistic operations, do inventory balancing and plan requests for semi-finished products in real time

Why it was created

ID reading + warehouse mapping + machinery tracking = a digital twin of your warehouse

The System aims to ensure:

Availability of information



Reduced human factor



Material tracking: Marking, sampling, dispatcher control and registration of warehouse operations, warehouse mapping, inventory monitoring, preparing data for data collection terminals

Cyber-Physical Function

Identification and tracking of warehouse machinery and stock items in physical space: Positioning of cranes, transfer cars, stock items; machine vision and other identification techniques

Functional Subsystems


  • Related systems: ERP, sales management, procurement management, production planning, reference data


  • System Core: Non-functional modules responsible for management, access control, integration
    • Warehouse Management: Inventory checks, parameter-based search, transfer of data to interfacing systems, integration with identification and marking subsystems, personnel task management
    • Inventory Accounting and Balancing: Material genealogy, quantitative accounting, item-by-item accounting, accounting for items together with and in the containers
    • Order Handling (as orders arrive)
    • Shipping – Generation of shipping documents
    • Warehouse on Wheels – Monitoring of materials that are still on trucks waiting to be unloaded at the warehouse
    • Marking
    • Reports
  • Warehouse Personnel Workstation (mobile workstations are included)
  • Interfacing systems: Transport management, production management (MES of a production facility), shipping management (shipping documentation), quality control


  • Integration Platform Core: Non-functional modules responsible for access control, integration, monitoring
  • Material Tracking – Registration of warehouse events
  • Warehouse Building Workstation (mobile workstations are included): Crane Operator Workstation, Warehouse Manager Workstation
  • Warehouse Dispatcher Workstation – Visualization
  • Administrator Workstation – System monitoring


  • Positioning of stock items and warehouse machinery on the warehouse map
  • Video registration of products (coils)
  • Interfacing systems: Process control systems responsible for cranes, transfer cars, car dumpers and other equipment


  • Marking
  • Подсистема технического зрения
  • Подсистема подсвечивания зоны наклейки бирки
  • Подсистема позиционирования кранов
  • Подсистема позиционирования прочей складской техники (телег)
  • Подсистема идентификации вагонов
  • Подсистема идентификации автотранспорта
  • Подсистема позиционирования вагонов
  • Мобильные терминалы сборы данных

Digital Warehouse Components

Software Tools

Cyber-physical platform - Парадигма (L2)

Information platform - MES.Builder (L3)

ИНКА 4.0 (L2+L3)

Siemens Logistics (L3) и WinCC OA (L2)

Wonderware AVEVA (L2+L3)


Pre-Project Activities

Initial inspection

Preparation of a design assignment

Design work


Factors that help choose the best solution

Constraints (warehouse capacity, how items are stored)

Physical conditions

Options: Existing monitoring and shipping systems

Basic configuration: Hardware and software

Integration (with interfacing systems)

Advantages for the Management

Online tracking of materials at the warehouse areas

Online search for material, faster shipping

The frequency of manual inventory checks can be reduced to two times a month

Jobs can be sent to crane operators in online mode

Automatic verification of the ID of a shipped product against the so-called shipping passport (security)

Consistency of shipping operations

Online generation of shipments with the current location displayed

Slab Tracking

Slab Tracking at the Slab Yard. Warehouse Manager Workstation

Slab Tracking at the Slab Yard. Crane Operator Workstation

Major Projects

Recognition of slab IDs and the IDs of transportation units at the entry to the warehouse area

Recognition of the IDs of transportation units and product IDs at control points

Tracking system for roller tables and delivery/discharge conveyors

Product tracking on roller tables and conveyors, recognition of product IDs at control points. Acquisition of additional data from process control systems

Crane Positioning System

Accurate positioning of cranes, determining the number of items being lifted and lowered, recognition of product IDs, acquisition of additional data about the crane status

Transfer Car Positioning System

Accurate positioning of transfer cars. Determining the number of items being transported, recognition of product IDs, acquisition of additional data about the transfer car status

Dead-End Railway Car Positioning System

Accurate/zonal positioning of railway cars on the dead-end track

Tag Recovery System

Installing tag printers, marking machines, Tag Recovery Workstation. Developing the Tag Recovery Workstation functionality. Implementing necessary interlocks with the main process control system.

Video Surveillance System

Installing video cameras, Video Surveillance Workstation.

Data Processing System. Hardware & Software Platform

Designing a server cluster (virtual machines) for the System

Digital Warehouse. System Core

Acquisition of data from various process control systems, mathematical processing, data processing, integration with MES, data storage

Warehouse Manager System

Implementation of the Warehouse Manager Workstation functionality

Crane Operator System

Implementation of the Crane Operator Workstation functionality

Roller Table/Conveyor Operator Workstation

Implementation of the Roller Table/Conveyor Operator Workstation functionality. Integration with the existing control systems.

Improving the existing MES systems

Developing interfaces on the side of the existing MES systems of a production plant. Enhancing the functionality of the MES workstation, modifying the business processes, writing handlers for the Digital Warehouse data. Preparing data to be sent to the Digital Warehouse system.

Mobile Terminals System

Installing mobile terminals to collect warehouse data. Implementing the functionality of data collection terminals: linking items stored at the warehouse, doing inventory checks, viewing the product information, scanning tags, printing tags, checking in and scanning transportation units, linking products to transportation units.

Process control networks, wireless networks

Setting up wired and wireless process control networks at the warehouse premises

Equipment and Interface Testing System

Acquisition of data for testing the Digital Warehouse system. Developing the Testing Workstation functionality