The connected warehouse
Optimizing logistics with real time inventory intelligence
Project Background
New Zealand Safety Blackwoods (NZSB) managed complex logistics across multiple warehouses with legacy systems, causing challenges in real time inventory visibility, order accuracy, and resource allocation. They needed a robust, mobile first solution to streamline operations, reduce errors, and scale for major clients like Fonterra and Air New Zealand. The goal was to replace paper based processes with a digital, data driven system integrated with their core business systems.
Developing a native mobile warehouse management system for real time inventory and logistics optimization
Objectives
Enable real-time inventory management: Provide live visibility into stock levels across all warehouses to reduce stockouts and overstocking.
Improve order accuracy & fulfillment: Digitize picking, packing, and shipping to minimise human error and speed order cycles.
Integrate advanced measurement: Use IoT technology to automate capturing weight and volumetric data for accurate logistics planning.
Ensure scalability & integration: Build a solution that grows with the business and integrates seamlessly with existing ERP and inventory systems on IBM i.
Optimise resource utilisation: Provide data-driven insights to improve workforce efficiency and reduce operational costs.
Key Features Delivered
Native mobile applications for iOS & Android: High-performance apps optimised for enterprise mobile computers (Honeywell CT40, Zebra TC58).
Real-time inventory tracking: Live sync of stock levels, locations, and movements across four warehouses, accessible from any device.
Advanced IoT integration: Utilised Intel RealSense depth cameras for automated, precise weight and volumetric measurement, eliminating manual data entry.
Streamlined order processing: Digital workflows for receiving, picking, packing, and shipping, with barcode scanning for accuracy.
Comprehensive reporting dashboard: Real-time reports on contractor usage, stock status, and operational efficiency for managers.
Seamless legacy system integration: Full two-way sync with the existing IBM i (AS/400) backend for orders, inventory, and customer data.
Our Approach
Digital400 adopted a full-stack, hardware-integrated approach. We mapped the complete warehouse workflow to identify key pain points and digital opportunities. Our design team used Figma to prototype the user interface, prioritising clarity and efficiency for workers using mobile devices in a fast-paced environment. We developed native iOS (Swift) and Android (Kotlin) apps to ensure maximum performance and reliability on enterprise-grade handheld devices like Honeywell and Zebra terminals. A robust .NET backend handles business logic and facilitates seamless integration with the core IBM i system, ensuring data consistency across operations.
Results
The Mobile Warehouse Management solution transformed logistics operations for NZSB, delivering clear gains in accuracy, speed, and cost control.
Significant productivity gains: Streamlined processes improved operational efficiency and productivity, allowing more orders with the same resources.
Enhanced inventory accuracy: Real-time visibility reduced stockouts and improved order fulfillment, boosting customer satisfaction.
Data-driven decision making: Improved tracking accuracy enabled faster, informed decisions and better cost control.
Future-proof scalability: The solution supports complex logistics for large clients like Fonterra and Air New Zealand, demonstrating robust, scalable architecture.
Reduced operational errors: Digitising manual processes and barcode scanning minimised shipping and receiving errors, saving time and resources.
Tech stack & hardware:
Swift, Kotlin, .NET, Figma
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