Inventory Tracking System
Category
Industrial electronicsIoT products
SERVICES
Electrical engineering
Mechanical design
Firmware development
Software development
Manufacturing
2024
THE CHALLENGE
Effectively managing storage for specialized parts, connectors, and fasteners can be a tough puzzle – but it’s one that most businesses can’t afford to ignore. Keeping track of vast inventories, organizing components, and maintaining accurate records demands significant time and resources. What’s more, failing to anticipate supply needs can do more than just slow things down: it can bring entire production lines to a standstill, all because a single critical part wasn’t on hand when needed.
That’s why smart inventory systems matter. Automating how you count, track, and refill supplies helps keep things running smoothly without wasting time or space. This kind of technology powers the massive warehouses of companies like Amazon, and supports the non-stop production flow in factories like Tesla’s gigafactories.
The Opportunity
MRO Supply has partnered with AJProTech to create an advanced inventory tracking system capable of measuring the weight and quantity of storage items.
MRO Supply is a leading U.S. supplier of materials and parts for equipment maintenance, repair, and operations with more than 100 delivery points throughout the United States. The company’s catalog includes more than 1 million parts in a variety of shapes, sizes, and applications stored in large warehouses where constant item counting and control are simply essential.
THE SOLUTION
AJProTech and MRO Supply has developed a versatile and multifunctional inventory tracking system that will take warehouse management and supply chain optimization to the next level. The advanced system is counting whatever you put in it and sending data to the server. The data can then be processed using advanced artificial AI tools to provide useful insights for keeping track of goods and keeping up the stock.
Multi-tiered metal shelves containing cells of various sizes accommodate the required number of objects of different shapes and sizes for storage, including, for example, bolts, nuts, wrenches, or screwdrivers. The powerful platform not only displays item data on a separate display, but also sends it to a custom web server, saving up to 95% of counting time.
- Measures weight. The most modern system measures the weight of objects on the shelves and immediately displays the information in ounces or pounds.
- E-Ink Display. Each cell features an E-ink display that shows real-time data: total weight, quantity of items, name and weight of each SKU, and a QR code for easy reordering.
- Data transfer to the web. Automate inventory control by transferring all system data to a web server.
- Real-time operation. The system updates data real time, detecting any additions or removals.
Our approach
AJProTech has a well-established product development process, refined through years of engineering experience. To tackle this challenge, we designed and developed a weight measurement system seamlessly integrated into a next-to-standard shelves that can be found in any fasteners warehouse. This system accurately measures the weight of individual boxes holding components on a warehouse rack.
Each cell is mounted on an individual weight sensor, which are then connected to a control module that measures, calibrates, and transfers information to the enterprise requirements planning (ERP) system via WiFi. This control module is implemented in a compact form factor mounted on the rear panel of the warehouse rack.
How it works
Our system streamlines part counting through intelligent weight-based measurement and real-time data processing. Here’s how it works:
Weighing the cell
Each cell is placed on an integrated digital scale. The system measures the total weight of the contents with high precision.
Wireless data transmission
The weight data is instantly transmitted to the web server via a secure WiFi connection, ensuring minimal latency and reliable performance.
Smart calculation
On the server, the system calculates the number of parts by dividing the total weight by the known weight of a single item. This allows accurate counting of identical components, even in high volumes.
Web interface display
The result is displayed in real-time through a user-friendly web interface. Operators can view the current part count and basket status from any connected device.This automated process reduces human error, speeds up inventory management, and ensures consistent accuracy in part tracking.
Mechanical design
Built from durable thin-sheet steel, each shelf supports up to 100 kg, offering exceptional strength and stability for warehouses of any size. While the exterior resembles a standard shelving unit, the system integrates a metal rack controller with a rugged touch-screen interface. Shelf quantity and configuration are fully customizable to meet specific client requirements.
Each shelf can accommodate up to 10 high-quality metal cells made from precision-engineered thin-sheet steel. Depending on operational needs, the storage cells can be adjusted in width. With each cell holding up to 10 kg, a single shelf can store up to 100 kg of goods.
This system delivers streamlined functionality, user-friendly operation, and space-saving efficiency — making it the ideal solution for companies focused on optimizing inventory management and enhancing supply chain performance.
Convenience, ease of use, and high functionality make this product an ideal choice for any company seeking excellence in inventory management and supply chain optimization. This system is able to ensure efficient utilization of storage space and replace the usual drawers or cabinets in warehouses.
Electronics design
One of AJProTech’s core strengths is our ability to design custom PCBs using off-the-shelf electronic components. Each component is fully compliant with industry quality and safety standards, ensuring reliable performance and regulatory alignment. This strategy enables us to deliver cost-effective, production-ready designs optimized for scalability and long-term use.
The electrical system powering the Inventory Tracking solution includes:
- Rack controller with integrated LCD display;
- Shelf-level controllers featuring energy-efficient E-ink screens;
- Precision weight sensors for real-time inventory monitoring;
- Robust wiring for reliable data and power transmission.
Let’s take a closer look at each component.
Electronics design – System controller
These systems are controlled by the main rack controller, which includes a custom PCB, an LCD touchscreen display, a metal case, and a Wi-Fi antenna. Connection to the board is accompanied by an audible alarm and a message on the screen. The rack controller collects data, sends commands to several boards, and then to the web service via an RS-485 interface.
The Rack controller PCB is based on the ESP32 chip, which performs the following functions:
- Collecting weight sensor data from shelf controllers;
- Sending data to the web service;
- Handling the calibration process;
- Powering the entire system;
- Updating the firmware over-the-air (OTA).
Electronics design – Weight Measurement unit
Each shelf has its own controller that communicates with weight sensors and E-ink controllers.
This performs the following functions:
- Collecting data from all weight sensors;
- Generating information for E-Ink display;
- Updating the information on the E-ink display.
Electronics design – E-Ink Controller
The E-Ink controller consists of a dedicated PCB powered by the STM32 chip and a 2.9-inch black-and-white E-Paper display. The screen displays the total weight, quantity of goods, QR code for ordering the goods, name, and weight of one SKU – unique stock identifier of the goods. This data will allow you to track stock balances and their location on the shelf, as well as provide optimization of supply chain management.
Let’s talk about your project
web server
In addition to the electrical system, the inventory tracking system includes a custom web server for viewing items, tracking performance metrics, and ordering missing and expiring items to stock. Including the web server is used to present the data of each rack controller connected to the cloud.
What does the web server contain?
- A list of all rack controllers registered in the database;
- List of customer’s domains and related information;
- SKU database and editing;
- All users;
- A page for creating a report.
Impact
- MRO Supply is ready to manufacture and distribute the Inventory Tracking System nationwide.
- The advanced inventory tracking system has piqued the interest of major U.S. Fortune 500 companies.
- Interested companies have pre-ordered the inventory tracking system to install and test it in their own warehouses and production facilities.
- Implementation of the automated system will not only simplify accounting and optimize supply chains, but will result in millions of dollars in savings and significantly reduce labor costs.
Interested in ordering?
Reach out to MRO Supply to discuss
