Applications / Operations Intelligence
Stock & Pallet Counting
Counts pallets, containers and stock positions across storage, line-side and dispatch areas, and flags empty racks, accumulation and shelf gaps.
See it in action
Four hundred pallets counted without a clipboard
Video slot — awaiting upload.
What it detects
Counting stock by walking it is slow, sampled, and out of date by the time it is typed in. Fogsphere counts continuously from the cameras already covering the racking, the line-side and the dock.
Pallet counting, movement and dwell
Counts pallets in each area, tracks their movement, and reports how long each has been where it is.
Container and carton counts
Counts containers, cages, bins and cartons across staging, storage and dispatch areas.
Empty-pallet and empty-rack accumulation
Detects empty pallets stacking up, and empty racks or bins that need replenishment.
Line-side inventory and material shortages
Reports line-side stock levels and flags an empty bin, a wrong container or a line-side stockout before the station starves.
Kanban lane and rack state
Reads empty-or-full rack state across kanban lanes and supermarkets, and flags replenishment delay.
Excess WIP and buffer build-up
Surfaces work-in-progress accumulating beyond its buffer, and material queueing where it should be flowing.
Shelf availability and stock-outs
Monitors shelf availability in stores and forecourt retail, and surfaces gaps before a stock-out costs a sale.
Laydown yard inventory
Counts pipe, conduit, cable reel, tray, rack and prefab module positions across laydown yards, and reports space utilisation.
Trailer and yard counts
Counts trailers in the yard, produces yard heatmaps, and flags wrong-zone parking.
Warehouse occupancy by area
Reports how full each aisle, block and staging area is, aggregated over time into utilisation.
FIFO and inventory dwell support
Reports inventory dwell time by position, supporting FIFO and FEFO discipline where the view allows.
Where it applies
Counting is the same primitive in a rack aisle, a kanban lane, a laydown yard and a shop shelf. The Q3 papers describe all four, and the same detection serves each.
How it works
Edge inference on the cameras you already have
Pallet, container and shelf-state detection runs on the edge device next to cameras already covering racking, line-side and dispatch. Counting is continuous rather than a cycle-count sample.
Zones, thresholds and schedules you configure
Draw each rack face, lane, block or shelf section, set the expected count or fill state, and set the schedule the check applies on. Bulk storage, line-side kanban and a shop shelf can each hold different rules.
Every event carries its own evidence
Each detection is logged with a timestamp, the camera and zone it came from, and a short clip. The record can be reviewed, exported or attached to an investigation without trawling through hours of footage.
Feeds the systems already in place
Events surface in Fogsphere Manager and route outward to the WMS, ERP, replenishment queue, planning dashboard or messaging channel operators already watch.
Risk & control objective
The control objective is a stock picture that matches the floor. System stock and physical stock diverge quietly, and the gap is usually only found at a cycle count, weeks after the movement that caused it.
The value is in the timing. An empty line-side bin flagged when it empties is a replenishment task; the same bin found when the station stops is a downtime event with a cause attached. The detection is identical — only the moment differs.
Counted continuously, the same data becomes a space argument. Which aisles carry stock that has not moved in six weeks, which staging area is permanently at capacity, and whether the yard needs more room or better discipline.
Related solutions
Count your stock from the cameras you already have
We will show you pallet counting, empty-rack detection and shelf-gap reporting on your own camera estate.