Optimized Warehouse Management System Leveraging Industry 4.0 Technologies

Abstract

This research presents an integrated Warehouse Intelligence Framework that brings together four AI modules - dynamic route optimization with Traveling Salesperson and A* pathfinding algorithms; fire detection with YOLO, spread prediction with the project frame-danger data, and shelf proximity; predictive analytics with ARIMA/Prophet/LSTM and Gradient Boosting models for stock anomalies and worker performance classification; and Best-Fit bin-packing with 3D space visualization - on a unified MERN + Flask platform. The overall system demonstrated 25% less total picking distance; 91% mAP in fire detection; under 8% MAPE in stock forecasting; 92% accuracy in worker classification; and an 18% increase in cubic-meter utilization, all in real time (20+ FPS, sub-second rerouting, 99% uptime) using only existing CCTV infrastructure. This modular, cost-conscious approach which breaks down silos between efficiency, safety, prediction and space utilization allows warehouses to confidently enter the adaptive Industry 4.0 space without retrofitting or installing proprietary hardware.

Country : Sri Lanka

1 A.A.A.S. Abeydeera2 P.D.M.P. Palihena3 P.A.S. Tharana4 V.S.D. Amangilihewa5 Dinuka Wijendra6 Prof. Samantha Rajapaksha

  1. Faculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka
  2. Faculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka
  3. Faculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka
  4. Faculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka
  5. Department of Information Technology, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka
  6. Department of Information Technology, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka

IRJIET, Volume 9, Issue 10, October 2025 pp. 174-181

doi.org/10.47001/IRJIET/2025.910024

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