Pallet counting on existing cameras with alerts for unscanned pallets
Cameras above the dock doors count pallets at receiving and dispatch. The system matches the count against WMS scans. When a pallet leaves without a scan, the shift lead gets a Telegram alert with a photo.
What hurts
Pallets are counted by hand and shortages surface only at stocktake. By then nobody knows which shift or which dock caused them.
The truck is waiting, the operator is rushing, and a scan gets skipped. The WMS says one number, the trailer holds another. The carrier disputes it and there is no evidence.
Cameras already hang over the docks, but footage is only reviewed after an incident. Finding the right minute in hours of video is slow and expensive.
What we build
- Audit of existing cameras over docks and receiving zones, connection over RTSP or ONVIF
- A model that counts pallets passing through each door and tracks direction
- WMS or ERP connection via API: document, dock, scanned quantity
- Reconciliation of camera counts with scans for every shipment
- Telegram alert for an unscanned pallet with a frame and a short clip
- Shift report and a morning report with discrepancies per dock
- On-site analysis server, so video never leaves your premises
- Event log where every decision is stored together with its frame
What you get
- A working system on the agreed docks, connected to your WMS
- Telegram bot and dashboard with events, frames and reports
- Accuracy report measured on your own warehouse footage
- Integration source code, documentation and all access credentials
- Shift lead guide and staff training session
How we measure the result
- Pallets dispatched without a scan, per shift and per dock
- WMS versus actual discrepancies caught on the day of dispatch
- Time to resolve a disputed shipment with a carrier
- Counting accuracy on a control sample of footage
Systems and stack
Industries
Questions
How much does it cost and what drives the price?
Projects start at $8,000. The price depends on the number of docks, camera condition, pallet types and how complex the WMS integration is. After a site survey we give a fixed estimate within 2-3 days. If we exceed it through our fault, we finish at our own cost.
Will our current cameras work?
Often yes, if a camera sees the dock from above or at an angle and provides an RTSP or ONVIF stream. What matters is that the forklift does not hide the pallet as it passes. If an angle is poor, we suggest moving one camera or adding one, not replacing the whole system.
Which WMS and ERP systems do you connect?
We connect via API or file exchange: SAP, Odoo, Microsoft Dynamics and custom systems. We need the dispatch document, dock number and scans. If there is no API, we agree on an export to a database or a sheet.
How accurate is the counting?
AI sometimes makes mistakes, especially with tightly stacked or wrapped pallets. So the event comes from the scanner, the camera checks the frame, and disputed cases are re-run. We measure accuracy on your site during the pilot and write it into the acceptance criteria.
How long does implementation take?
Six to ten weeks. A site survey and 1-2 weeks of discovery come first, then the build with weekly demos. We launch on one dock, verify accuracy, then add the rest. After launch we support the system under an SLA.
What happens if the internet goes down?
The analysis server sits in your warehouse, so counting keeps working offline. Events and clips are stored locally and sync to the dashboard and Telegram once the connection returns. Video stays on your premises throughout, which also simplifies GDPR questions.
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We reply within one business day. 30 minutes to tell you whether it is worth doing and what it costs.