A smart Industry 4.0 solution

July 2019 Industrial (Industry), CCTV, Surveillance & Remote Monitoring, Integrated Solutions

Warehouses are complex security environments. Hundreds of workers move thousands of items through aisles and corridors, making it difficult for security managers to detect inventory theft and track missing shipments. In an Industry 4.0 success story, the team at the Bosch Automotive Aftermarket distribution centre in Itupeva, Brazil, used the Internet of Things (IoT) to create a solution: their customised integration between video analytics and warehouse management software prevents theft, heightens efficiency and improves shipment tracking.

Located about 70 kilometres from São Paulo, the automotive distribution centre in Itupeva is a central hub for the entire South Americas region. The 26 000 square-metre facility processes 68 000 shipments of key components per year, so the sheer level of movement of items, pallets and warehouse personnel proves challenging to track from a logistics and security perspective.

A few years ago, the logistics team realised that inventory losses from theft were on the rise. Meanwhile, customer inquiries about misplaced items in shipments required lengthy research, putting the centre’s reputation at risk. This called for a change of approach.

Investigating the issue, it turned out that the security team was overwhelmed by the sheer amount of alarms. Every incident recorded by the video cameras required time-consuming manual investigation: whenever an employee entered a restricted aisle, personnel in the security control room received an alert to perform a cross-check in the warehouse management system. This was to confirm whether an active task had been assigned to that aisle. If not, security on the warehouse floor would be called to investigate. But with thousands of alerts and false alarms per day, this proved humanly impossible.

Integrated warehousing and video

To solve the challenges, the Bosch experts worked for over one year to automate the time-consuming manual checks: the approach combines the Intelligent Video Analytics (IVA) technology built into Bosch cameras with a customised configuration of the Bosch Video Management System (BVMS), and an interface to the centre’s warehouse management system.

From a technical perspective, it’s a combination of existing technology with networked information: all of the distribution centre’s 200 security cameras, including the high-definition Bosch Flexidome IP series are fitted with Intelligent Video Analytics (IVA). This built-in function processes image data in real time and detects suspicious activities by means of an algorithm. In the first step, the team ‘taught’ the cameras to recognise objects in the warehouse such as forklifts and shipment items. Once the security system had learned to identify these objects, it was ready to interface with the centre’s logistics system.

In the next step, the team created a direct interface between warehouse management system and the BVMS. Creating the connection adds a new level of intelligence to the centre’s video surveillance: the smart cameras now act as IoT sensors that can identify products stored in the warehouse management system software, which currently catalogues 13 497 part numbers. The system also automatically cross-checks security incidents with scheduled tasks in the warehouse system.

Thanks to this smart automation, operators only receive alarms when a worker enters an aisle without a task – and no alarm is triggered if the worker passes through without stopping. As a direct result, the number of security events dropped from several thousand to about 100 per day and incidences of theft receded as well.

Streamlined logistics

From an operations perspective, the Industry 4.0 solution not only boosts security but also answers the centre’s need to replace the time-consuming manual tracking process for misplaced items and shipments. Whereas the logistics team previously required several hours to manually locate a lost item, every item now receives a tracking number connected to video recordings documenting its movements. This level of transparency allows the logistics team to solve inventory problems within minutes instead of hours.

Ever since the system has been successfully rolled out, the team in Itupeva has used the new level of oversight to unlock additional benefits: four solid fences guarding sensitive areas in the warehouse could be replaced by virtual fences, meaning security zones defined in the video management system. This unlocks a new level of flexibility for changing the arrangement of aisles and shelves in the warehouse – as is frequently required – entirely without compromises on security. What’s more, the customised Industry 4.0 solution drastically reduces inventory costs by performing virtual inventory in real time and is expected to amortise itself in less than a year.



Credit(s)




Share this article:
Share via emailShare via LinkedInPrint this page



Further reading:

How to stop security threats early
J2 Software Cyber Security Integrated Solutions
Integrating a security ecosystem allows one to better protect the company, while also better understanding and improving the company’s risk posture.

Read more...
SA’s industrial challenge
Industrial (Industry)
The rapidly increasing uptake of artificial intelligence, machine learning and the Internet of Things in manufacturing, makes production facilities extremely vulnerable to malevolent actors.

Read more...
Suprema integrates biometric access control with Genetec
Suprema News CCTV, Surveillance & Remote Monitoring Access Control & Identity Management
Suprema has announced the successful integration of its biometric access control products with Genetec Security Center, a unified security platform that connects security systems, sensors and data in a single intuitive interface.

Read more...
The state of the distribution market
ESDA (Electronic Security Distributors Association Bosch Building Technologies Dark Horse Distribution Elvey Security Technologies Regal Distributors SA G4S Secure Solutions SA Editor's Choice Security Services & Risk Management
The distribution industry has evolved over the years and its current challenges simply mean another change is in the wind, for those who can take the next step.

Read more...
Premium forensic analytics
Milestone Systems News CCTV, Surveillance & Remote Monitoring Government and Parastatal (Industry)
With the introduction of XProtect Rapid REVIEW, powered by BriefCam, Milestone’s customers will be able to accelerate investigations and find what they are looking for with speed and accuracy.

Read more...
City surveillance in South Africa
IDEMIA Government and Parastatal (Industry) CCTV, Surveillance & Remote Monitoring Integrated Solutions
Smart cities and their smarter, more responsible eye in the sky; a look at the video surveillance landscape in South Africa.

Read more...
Seeing without being seen
Government and Parastatal (Industry) CCTV, Surveillance & Remote Monitoring
Video surveillance should be as discreet as possible to protect the aesthetics around the legendary promenade in Cannes.

Read more...
Object monitoring technology
Dahua Technology South Africa Government and Parastatal (Industry) CCTV, Surveillance & Remote Monitoring Integrated Solutions Products
Powered by deep learning algorithms, the WizMind 5 Series can accurately detect six types of objects: luggage bag, backpack, box, shopping bag, bicycle and motorbike.

Read more...
Securing smart devices in OT environments
Cyber Security Security Services & Risk Management Industrial (Industry)
The Industrial Internet of Things (IIoT) gives devices a link to the Internet so that users can interact with them in realtime, draw and analyse data for statistical or predictive analysis.

Read more...
Speed up service delivery
News Integrated Solutions Government and Parastatal (Industry)
My Smart City platform speeds up service delivery in Cape Town, driven by private and public sector collaboration.

Read more...