The Challenge
A Fortune 500 technology company operated a 200,000 square foot data center with 1,200+ racks, 8,000+ servers, and 15 different monitoring systems. Their operations team of 45 people relied on a combination of spreadsheets, legacy DCIM software, and physical whiteboard maps to track capacity, environmental conditions, and maintenance schedules.
The breaking point came when a cooling failure affected 200 racks and the team spent 4 hours identifying which customer workloads were impacted — because their rack mapping spreadsheet was 3 months out of date.
The Implementation
TwindUp deployed a complete digital twin in three phases over 90 days. Phase one captured the facility geometry using Matterport scans and integrated with the existing floor plan CAD files. Phase two connected 11 of the 15 monitoring systems through pre-built integrations and custom API connectors for the remaining four. Phase three implemented automated workflows for capacity alerts, environmental threshold breaches, and maintenance scheduling.
The entire deployment was completed without any production downtime and required only 2 hours per week of the facilities team's time during implementation.
The Results
Within 60 days of full deployment, the operations team reported measurable improvements across every key metric. Mean time to identify affected assets during incidents dropped from 4 hours to 12 minutes. Capacity planning accuracy improved from 70% to 97% because the team could finally see real-time utilization at the rack level.
Environmental compliance documentation that previously required 3 full-time days of manual data gathering each quarter was automated to generate continuously. The team estimated 2,000+ hours of annual labor savings from eliminated spreadsheet maintenance and physical walkthrough requirements.
Ready to see it in action?
Book a Demo