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Back[ Coventa ]Case Study

[ PHYSICAL AI OPERATIONS ]LIVE

Motion™

Operate the physical world on uptime SLAs. Digital twins, simulation and synthetic data, and multi-OEM robotic fleet orchestration run physical operations as a managed outcome — with value captured in software and fleet management rather than hardware, and physical actions human-gated.

MOTION // TWIN SYNC

// Problem

The Problem

Physical operations are planned with tools that cannot simulate the plan. Layout, throughput and fleet-sizing decisions are made in spreadsheets and validated only after capital is committed, so mistakes are discovered in concrete. Robotics compounds this: fleets from different vendors arrive with incompatible control stacks, so an operator with three OEMs runs three consoles and has no unified view of availability or throughput.

  • Planning decisions are validated after commitment, when they are expensive to reverse.
  • Multi-OEM fleets fragment into separate control stacks with no common availability picture.
  • Training perception models requires edge-case data that real operations rarely produce safely.
  • Vendors sell hardware and disclaim the outcome, so uptime is nobody's contractual problem.

// Overview

Motion runs physical operations against a live digital twin. Layout, routing and fleet-sizing decisions are simulated before commitment, and the twin remains synchronised with the floor in operation, so deviation is visible against plan rather than discovered at the end of a shift. Synthetic data generation supplies the edge cases that perception models need and real operations cannot safely produce. Fleet orchestration is multi-OEM by design, presenting one availability and throughput picture across heterogeneous robots. Physical actions are human-gated; the commercial model is SLA-backed on uptime and throughput.

// AI System

Why AI

Simulation and synthetic data address the fundamental constraint of physical AI: you cannot collect enough real-world failure data safely, and you cannot iterate on a floor plan that has already been built. Training in a twin and transferring to the real system inverts the order — the expensive decision is tested before it is made. Orchestration across OEMs is a planning problem over heterogeneous capability, which is exactly where a model outperforms a per-vendor scheduler.

// Specs

Specifications

TWIN
Live digital twin, synchronised with floor state
SIMULATION
Layout, routing and fleet-sizing tested pre-commitment
DATA
Synthetic generation for perception edge cases
FLEET
Multi-OEM orchestration under one availability view
SAFETY
Physical actions human-gated
COMMERCIALS
SLA-backed on uptime and throughput

// Features

Features

  1. 01Capital decisions simulated in the twin before commitment, not validated after.
  2. 02Twin stays synchronised in operation, so deviation from plan is visible live.
  3. 03Synthetic data supplies perception edge cases real operations cannot safely produce.
  4. 04One availability and throughput view across robots from different vendors.
  5. 05Physical actions gated by human authorisation at defined boundaries.
  6. 06Contracted on uptime and throughput, so the outcome is the vendor's problem.

// Architecture

Architecture

SIM-TO-REAL FLOW

Runtime · one item, left to right


  1. 01Floor Telemetry
  2. 02Digital Twin Sync
  3. 03Simulation + PlanningLayoutRoutingFleet SizingSynthetic Data
  4. 04Fleet Orchestration
  5. 05Human Safety Gate
  6. 06Physical Execution

dashed = the inference step, where the system exercises judgment

System stack

Data in · decisions out

01

Sources

The physical floor

Robot fleet telemetryAMR / AGV APIsWMS / WESCameras & sensorsLayout CADOrder & labour data

02

Ingestion

Twin in sync

Telemetry streamingsub-secondLayout digitisationSynthetic data generationOrder-flow replay

03

Ontology

The floor as objects

Robot · TaskZone · Aisle · StationOrder · WaveScenarioPolicy

04AI

Intelligence

Simulate, then act

Digital twin simulatordiscrete-event + physicsRouting & congestion modelFleet sizing optimiserLayout scenario engineSim-to-real validation

05Human

Human control

Operations approve the change

Ops manager approvalSafety envelopeScenario compareRollback

06

Actions

Written back

Fleet routing policyWMS wave planLayout change order

Observability

Every model call traced; evals run on real cases, not anecdotes.

Governance

Entitlements enforced at retrieval; rules versioned by the organisation.

Write-back

Systems of record are written only through the approval gate.

Execution telemetry returns to the twin; the loop closes at the floor.

// Impact

Impact

~30%
Lower planning costindicative target
SLA-backed
Robot availabilitycommercial commitment

Interested in Motion?

Let's twin your floor before you commit the capital.

Get in touch
// End of case studyMotion™