Skip to content
Home
Case Studies
Warehouse Automation with IoT + AWS
From Manual Stock Checks to Real Time, IoT Powered Warehouse Visibility
A Warehouse Operator’s Journey to Fewer Errors, Faster Fulfilment & Smarter Inventory Control
About the Client
A warehouse operator managing thousands of SKUs across multiple storage zones. Their inventory process relied heavily on manual stock checks, spreadsheets, and delayed updates, leading to errors and slow fulfilment.
Key Challenges:
- Manual stock counting
- Inaccurate inventory records
- Delayed updates from the warehouse floor
- High error rates in order picking
- No real time visibility
- Difficulty identifying stock discrepancies
The Warehouse Manager described the situation clearly:
“We were always reacting to problems instead of preventing them.”
The company needed a modern, automated system to track inventory in real time.
The Challenges
The Problem: Manual Inventory Processes Were Slowing Down Operations
Warehouse staff relied on:
- Clipboards
- Paper pick lists
- Manual data entry
- End of day stock updates
This caused:
- Frequent stock discrepancies
- Incorrect order fulfilment
- Delayed shipments
- High labour costs
- Low visibility for management
The leadership team wanted a solution that would:
- Automate stock tracking
- Provide real time visibility
- Reduce human error
- Improve fulfilment speed
- Integrate with existing systems
They partnered with Aus NewTechs to build an IoT powered warehouse automation system.
Our Solutions
How Aus NewTechs Built a Real Time IoT + AWS Warehouse Automation System
IoT Sensors Installed Across Warehouse Zones
We deployed IoT sensors to track:
- Stock movement
- Shelf occupancy
- Temperature (for sensitive goods)
- Pallet location
- Item scanning events
These sensors send data to AWS in real time.
Real Time Inventory Dashboard (AWS Cloud)
We built a secure dashboard showing:
- Live stock levels
- Inbound/outbound movement
- Low stock alerts
- Zone by zone activity
- Pick/pack progress
- Discrepancy alerts
Managers can now see everything happening on the warehouse floor instantly.
Automated Stock Reconciliation
The system automatically:
- Compares expected vs. actual stock
- Flags discrepancies
- Suggests corrective actions
- Logs movement history
This eliminates manual reconciliation.
Mobile App for Warehouse Staff
Staff can now:
- Scan items
- Receive pick lists
- Update stock in real time
- Report issues
- Track pallet movements
Everything syncs instantly to the cloud.
Predictive Analytics for Inventory Planning
The AI analyses:
- Stock turnover
- Seasonal demand
- Picking frequency
- Storage utilisation
This helps the company plan better and reduce overstocking.
The Transformation:
Smarter Warehouse, Faster Fulfilment, Fewer Errors
70% Reduction in Stock Errors
Real time tracking eliminated manual mistakes.
Faster Order Fulfilment
Pickers receive accurate, real time instructions.
Improved Inventory Accuracy
Managers always know exactly what’s in stock.
Full Warehouse Visibility
Live dashboards show activity across all zones.
Lower Operational Costs
Less manual labour, fewer errors, faster processes.
What the Client Said
“The IoT system has transformed our warehouse. Errors dropped, fulfilment is faster, and we finally have real time visibility.”
Why Logistics & Warehouse Operators Choose Aus NewTechs
- ➜ Deep expertise in IoT + AWS automation
- ➜ Strong understanding of warehouse workflows
- ➜ Proven experience with inventory optimisation
- ➜ Affordable solutions designed for SMBs
- ➜ Hybrid onshore/offshore delivery for cost efficiency
Ready to Automate Your Warehouse with IoT + AWS?
Let’s help you reduce errors, improve fulfilment speed, and modernise your warehouse operations.