IoT-Based Inventory Management System
Client
A US based leading tech company specializing in retail automation aimed at simplifying retail operations to maximizing ROI.
Problem Statement
The Client sought a smart, IoT-based solution for inventory management that would provide real-time, accurate stock updates and automate inventory replenishment, without the need for visual monitoring or complex Infrastructure.
Solution
To achieve this, we developed a custom cost-efficient IoT based smart inventory system. This system used high precision weight sensors to track item removal and replacement, giving accurate real time data on inventory levels. It also had automated alerts to notify store managers and vendors when stock levels reached a preset reorder point to streamline inventory replenishment. The system provided an intelligent solution that could operate in a range of environments, from room temperature to cold storage and deep freezers.
Approach
- System Architecture and Research
High-Precision Load Cells: We integrated load cells that measured weight changes as small as 1g, ensuring accuracy in tracking product movement.
Low-Power Microcontroller: A low-power microcontroller was selected to process the weight data efficiently while maintaining long battery life (15+ days on a single charge).
Wi-Fi Connectivity: Real-time data transmission was made possible via a reliable Wi-Fi module, allowing updates to be sent to servers instantly. Power Management: To ensure continuous operation, we implemented energy-saving sleep modes for the microcontroller, enabling low power consumption without sacrificing performance.
- Prototype Development
The initial prototype was completed within 20 days. The system included:
Custom PCB Design: The PCB was designed to integrate all the necessary components, such as high-precision load sensors, a microcontroller, and a Wi-Fi module.
Dual-Controller Power Management: A dual-controller design ensured that the primary controller went into low-power mode while the secondary controller remained active, ensuring continuous weight monitoring and seamless communication.
OTA Firmware Updates: We implemented an Over-the-Air (OTA) update mechanism that allowed all deployed devices to receive firmware updates simultaneously, ensuring futureproofing and consistency across all units.
- Testing and Iterations
Accuracy Testing: The system underwent rigorous functional testing to ensure the accuracy of weight measurements across a range from 1g to 2kg.
Real-Time Updates: We tested the latency of real-time data transmission to ensure immediate alerts on item removal or replacement.
Power Consumption: We validated the system’s ability to operate on minimal power for extended periods, meeting the client’s battery life requirements.
- Environmental Optimization
Cold Storage and Freezer Operations: The devices were coated with a conformal layer to prevent condensation and ensure reliable performance in extreme cold.
Humidity and Heat Resistance: We tested the devices in high-humidity and high-temperature conditions to ensure robust operation in diverse environments.
Business Value
The IoT-based Smart Load Cell System transformed inventory management for the client, delivering many business benefits:
- Cost Savings: Automated stock tracking reduced manual labor and operational expenses by 35%.
- Real-Time Inventory Updates: Real-time inventory updates and alerts improved stock accuracy, minimizing shrinkage.
- Lower Energy Costs: Low-power design ensured efficient energy usage.
- 50+ Locations Optimized: Deployed seamlessly across the globe in supermarkets, warehouses, and pharmacies without expensive infrastructure upgrades.
A future-proof, intuitive design with excellent engineering.
