Overview
This leading manufacturer in the World has multiple bays in their warehouse and they want to assign the pick list for each customer based on the truck number but they were not able to determine the vehicle entry exit time from each dispatch docks even though they had common factory entry exits.
Previous System - RFID Challenges
Previously they were using RFID tags for tracking vehicles. On security entry they were provided with RFID cards that needs to be placed in the windshield and when it enters the bay it detects the entry exit time. Their existing RFID investment was huge and not working effectively because:
- Too many manual interventions required
- RFID tags were not aligning properly to the scanner
- Inconsistent detection rates
- High maintenance and operational costs
Our Solution
They asked us to solve this problem, and we used regular CCTV cameras at each dock to detect the vehicle presence and used AI inference to record vehicle numbers and integrate with their existing system to automatically fetch the picklist based on vehicle numbers.
1. CCTV + AI Inference
- Regular CCTV cameras installed at each dock
- AI inference to detect vehicle presence
- Automatic license plate recognition
- Real-time entry and exit time tracking
2. System Integration
- Automatic picklist fetching based on vehicle number
- Seamless integration with existing warehouse systems
- Real-time dashboards and reports
- Dispatch dock utilization analytics
Technical Achievement
We had to train the model in such a way that it works for all types of Indian trucks with challenging conditions:
- Poor painting and faded number plates
- Partial occlusions and obstructions
- Garlands and decorations on trucks
- Dirt and wear on license plates
- Various truck types and configurations
Still we were able to provide outstanding accuracy that's exponentially better than current RFID tags and even ready-made ANPR cameras.
Key Differentiator - Bidirectional Detection
Vikbot Fleetbot is intelligent enough to determine the direction of vehicle as typical warehouse dock. Truck enters in reverse and leaves in forward which is not supported by regular ANPR cameras as it works just on one direction.
- Entry Detection: Trucks enter the dock in reverse gear
- Exit Detection: Trucks leave the dock in forward gear
- Direction Tracking: Accurate entry and exit time recording for each movement
This bidirectional detection capability is a unique feature that regular ANPR cameras cannot support, making our solution ideal for warehouse and logistics environments.
Results
- Exponential Accuracy Improvement: Outperformed RFID tags and ready-made ANPR cameras
- Reduced Manual Intervention: Automated tracking eliminated RFID card management
- Cost-Effective Solution: Leveraged existing CCTV infrastructure
- Bidirectional Tracking: Successfully handles both forward and reverse vehicle movements
- Automatic Picklist Assignment: Seamlessly fetches picklists based on vehicle numbers
Conclusion
The AI-powered fleet tracking solution transformed this manufacturer's warehouse operations. By replacing their expensive and ineffective RFID system with intelligent CCTV cameras and AI inference, we delivered a solution that provides accurate vehicle tracking, entry/exit time recording, and automatic picklist assignment. The bidirectional detection capability specifically addresses the unique movement patterns of warehouse docks, making Vikbot Fleetbot the ideal choice for fleet management in industrial settings.