Pallet counts from phone photos and rack occupancy from fixed cameras, reconciled with warehouse records to highlight discrepancies

We built a warehouse counting system that combines fixed-camera rack checks with pallet counting from a phone photo. Teams can see occupied and empty rack positions, count pallet stacks in the yard, and compare those observations with warehouse records.

The workflow connects capture, delivery-note checks and reconciliation, directing staff to the locations where the physical count and the system record disagree.

Warehouse records only stay useful when they match what is on the floor. Finding free rack space can mean walking the aisles, while empty-pallet returns are often counted by hand and checked against a delivery note under time pressure.

Small differences accumulate between physical movements and recorded stock. By the time a full stocktake uncovers them, staff have to retrace work across locations, paperwork and system entries. The challenge was to make routine checks easier and make discrepancies visible sooner.

We built two capture workflows around the equipment staff already use. Fixed cameras scan the aisles on a schedule, and a rack-occupancy model marks mapped positions as occupied or empty. Available locations feed the putaway list so teams can find space without a separate aisle walk.

For stacks in the yard, the mobile app lets a driver or checker take a photo. The system identifies stacks, counts the visible pallets, separates pallet types and reads visible barcode labels. Staff can review the count, compare it with the delivery note and sign off the check in the same flow.

Counts are reconciled with warehouse records, with mismatched locations flagged for a person to check. This turns the output of the vision system into a focused review queue, linking each observation back to the warehouse workflow instead of creating another stand-alone count.