Smart Warehouse Management System

To deploy a smart warehouse management system, consider adopting a hybrid approach that combines LoRaWAN and Bluetooth RTLS technologies. This utilises LoRaWAN’s long-range, low-power capabilities for extensive coverage and Bluetooth’s strength in close-range, high-density data transfer and precise location tracking.

Inventory Management (FIFO, Stocktake, Theft Reduction)

For accurate inventory, including a First-In, First-Out (FIFO) model, and to reduce theft, use a system that combines Bluetooth and LoRaWAN devices.

• Bluetooth Low Energy (BLE) Beacons: Attach these small, battery-powered beacons to individual items or pallets. Each beacon transmits a unique ID.

• Bluetooth Gateways: Install these gateways at key points in the warehouse, like aisles, entryways, and docks. They scan for and collect data from any BLE beacons within their range.

• LoRaWAN Backhaul: The gateways, which have both Bluetooth and LoRaWAN radios, send the collected beacon data over a long distance using the LoRaWAN network to a central server. This is especially useful in large warehouses where running a wired connection to every gateway isn’t practical.

This setup provides real-time visibility of your inventory. As pallets move, the gateways track their location and time of entry, which allows the system to enforce a FIFO model by flagging the oldest pallets for shipment. The constant tracking also improves stocktake accuracy and helps reduce inventory theft by alerting staff to unauthorized movements.

Worker Safety and Equipment Monitoring

You can enhance worker safety and monitor equipment by using a similar tracking method.

• Worker Safety: Workers can wear BLE tags on their vests or hard hats. The system can trigger an alert if a worker enters a restricted zone near heavy machinery or if they haven’t moved for a set period (a “man-down” scenario). Gateways on forklifts can also detect nearby worker tags and sound an alarm to prevent collisions.

• Equipment Monitoring: For critical equipment like pump motors and HVAC units, use LoRaWAN-enabled sensors that can directly measure parameters like vibration, temperature, and current draw. These sensors transmit data over the long-range LoRaWAN network to a central server. The data can be analysed to detect anomalies, such as a motor vibrating excessively, which could signal an impending failure. This enables predictive maintenance, letting you perform repairs before a critical breakdown occurs.

Centralized Management

All the data from the Bluetooth RTLS gateways and LoRaWAN sensors is sent to a central network server, and then to an application server. This server processes, analyses, and visualises the data on a dashboard. This dashboard offers a comprehensive view of the entire operation, including:

• Real-time inventory levels and locations.

• The location and status of all personnel and equipment.

• Alerts for safety incidents or equipment issues.

Smart Warehouse Management with Bluetooth RTLS and LoRaWAN

This unified approach transforms a warehouse into a smart environment that is more efficient and safer. 

Contact us to know more about smart warehouse management solutions built on LoRaWAN and Bluetooth asset tracking devices.