Otto Group has implemented a centralised, AI-driven virtual control system to coordinate autonomous robots across its logistics operations, working with Reply and NVIDIA on the development and deployment of the platform. The system is designed to support the training, simulation and orchestration of both mobile and stationary robotic systems within warehouse environments.
At the core of the system is a high-fidelity digital twin that replicates physical warehouse layouts and operations, including the position, movement and interaction of robotic assets. The digital twin was developed by Roboverse Reply, a robotics-focused unit of Reply, and is intended to provide a data-driven basis for operational analysis and continuous optimisation.
The digital twin underpins a “Robotic Coordination Layer” developed by Otto Group one.o, the technology and consulting arm of Otto Group. This layer connects the virtual environment with operational systems such as robot fleet management software and warehouse management systems, enabling centralised monitoring and coordination of multiple robotic fleets. It also allows warehouse configurations and robotic deployments to be simulated and adjusted virtually before being implemented on site, with the aim of reducing downtime and supporting peak-period operations.
To generate the required level of accuracy, Roboverse Reply used scanning and camera systems mounted on Spot, a mobile robot developed by Boston Dynamics. The captured data is processed to create detailed three-dimensional models of the warehouse environment. The simulation environment is built on NVIDIA’s Omniverse platform and incorporates NVIDIA Isaac, its robotics development framework, to support simulation, training and performance measurement across different robotic configurations.
Kai Uwe Ernst, Executive Partner at Reply, said that the objective of the digital twin extends beyond spatial modelling. “Creating a digital twin is more than just mapping a space – it’s about enabling intelligent orchestration at scale,” he said, adding that the platform is intended to allow different robotic systems to communicate and operate together within complex logistics environments.
The pilot deployment is being launched at a Hermes Fulfilment logistics centre in Löhne, Germany. Hermes Fulfilment is part of Otto Group’s logistics network, and the site is expected to serve as a reference model for further rollouts at other locations.
Kay Schiebur, Member of the Executive Board for Services at Otto Group, said the group’s earlier investments in AI and robotics had demonstrated operational potential. “With NVIDIA and Reply, we are now ready to take intelligent automation to the next level,” he said, describing the coordination layer as a structural foundation for scaling robotic solutions across the company’s logistics operations.
