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Three dimensional model of a facility with coordinated cranes, lines and dense coil storage

See how it works before you build it.

CareGo creates a virtual model of your facility, equipment, and workflows so you can explore material flow, test how systems work together, and identify bottlenecks before construction begins or changes are made on the floor.

See simulationTalk to CareGo

Concrete is expensive.
Moving something on a screen is not.

Every facility decision has consequences. Once the building exists, those decisions become expensive to change.

  • Move a bay ten feet

  • Change a crane span

  • Add storage rows

  • Change staging

  • Move production

  • Increase inventory

A Digital Twin lets you test those decisions first.

This is not a prettier floor plan.

A rendering shows you what it looks like.

Blue toned isometric architectural rendering of an empty warehouse
  • Building
  • Equipment
  • Walls
  • Crane

A digital twin helps you understand how it works.

Blue toned isometric digital twin model showing material, equipment and flow
  • Building
  • + Material
  • + Equipment movement
  • + Product flow
  • + Storage
  • + Operational relationships

The question is not “Does the facility fit?”
It is “Will the operation perform?”

Walk through the operation before it exists.

  1. Overhead crane working above steel coils in storage
    1

    Material flow

    See how product moves from receiving through storage, production, and shipping.

  2. Coil bay running east to west with material staged for movement
    2

    Crane movement

    Understand how cranes travel, overlap, and interact.

  3. Coils in dense storage under an automated crane
    3

    Storage

    Explore layout, density, accessibility, and retrieval paths.

  4. Material moving toward production inside a CareGo served facility
    4

    Production

    See how material reaches production when it is needed.

  5. Steel coils resting on staging bunks
    5

    Staging

    Understand where material waits, for how long, and why.

  6. Material handed off between storage and shipping areas
    6

    Shipping and receiving

    Explore how inbound and outbound movements interact with the facility.

  7. View over full coil fields inside a large facility
    7

    Capacity

    Test what the environment can support as demand, inventory, and operations change.

A worked example

What happens if we change this?

Change the storage, layout, inventory, equipment, or material flow — and see the operational impact before making the decision.

Modeled variables

  • Move storage
  • Change layout
  • Increase inventory
  • Change equipment
  • Change product flow

Simulation complete

Isometric digital twin with a highlighted storage zone under testSimulated result

Compare the tradeoffs.

A decision is not good because one number improves. It is good when the whole environment performs better.

+22%
Storage capacity
+18%
Crane travel
+12%
Access time
-8%
Flow efficiency

Facility design creates the idea. Digital twins challenge it.

  1. 1

    Facility design

    Here is the proposed environment.

  2. 2

    Digital twin

    Now let us see what happens when it runs.

  3. 3

    Questions

    Does the product flow? Does storage work?

  4. 4

    Refine

    Change it.

  5. 5

    Test again

    Only then.

  6. 6

    Implement

    Make it real.

The loop keeps asking

  • Does the product flow?
  • Does storage work?
  • Does crane coverage work?
  • Are there bottlenecks?

A digital twin changes the decision before it changes the facility.

  • Reduce capital risk

    Test important assumptions before committing money to construction or equipment.

  • Find constraints earlier

    Identify bottlenecks while they are still design problems instead of operating problems.

  • Validate capacity

    Challenge whether proposed storage and layouts can actually support the expected operation.

  • Make better equipment decisions

    See how equipment fits into the broader flow before installing it.

  • Align the team

    Give operations, finance and leadership something tangible to review together before signing off.

One model. Different decisions.

  • CEO

    Will this environment support where we are trying to go?

  • CFO

    Are we putting capital into the right facility and equipment?

  • VP Operations

    Will this actually improve the way production runs?

  • Plant Manager

    Is this going to work when the real material starts moving?

Greenfield: Build it right.

Before the first piece of steel goes up, run the operation in the model.

  1. 1Design
  2. 2Simulate
  3. 3Review
  4. 4Change
  5. 5Validate
  6. 6Build

Basic Metals

42,000 sq. ft. new facility. CareGo integrated from the ground up.

Brownfield: Improve with confidence.

You do not have to build something new to test something new.

  1. 1Current layout
  2. 2Virtual model
  3. 3Proposed change
  4. 4Review impact
Interior of the Perrysburg facility served by CareGo

Toll processor

Three bays became two. Expansion avoided. More storage. Better flow.

See the kind of environments we are designing for.

  • Coils in storage at the Plant 19 3PL facility

    Plant 19

    • 4.3M tons annually
    • 1 operator
    • 2 coordinated cranes
  • Steel coils stored inside a steel mill

    Coating line

    • 350% more
    • coil storage
  • Interior of a CareGo served facility in operation

    Basic Metals

    • 42,000 sq. ft.
    • greenfield expansion
Explore case studies

Something everyone can see, challenge and understand.

  • Virtual facility
    model

  • Equipment
    visualization

  • Material
    flow

  • Floor
    plans

  • Design
    concepts

  • Collaborative
    review

High fidelity isometric digital twin model of a steel facility

Connected CareGo technologies.

See it before you build it.

Show us what you are planning to build or change. We will help you visualize how the environment will work before you commit it to the floor.

See simulationContact Us