Smart Inventory Scanner
Rugged handheld RFID/barcode scanner with a bespoke inventory management web portal.
What we delivered (snapshot)
- Custom embedded firmware on an NXP i.MX RT platform with RFID, barcode, and Wi-Fi stack.
- Web portal for real-time inventory tracking, stock variance alerts, and audit exports.
- IP65-rated ABS enclosure with rubberised grip insert and pistol-grip ergonomy.
The Challenge
An SME operating multiple warehouse sites needed to replace ageing handheld scanners that required a proprietary backend which was approaching end-of-life. The replacement had to integrate with their existing ERP via a REST API while also running fully standalone for up to 8 hours per shift without network connectivity.
The form factor had to be familiar to warehouse operatives (pistol-grip), survive drops to 1.5 m on concrete, and accommodate both 1D/2D barcode and UHF RFID scanning in the same unit. Off-the-shelf enterprise scanners were ruled out due to total cost constraints across 20 units.
Constraints
Timeline
10 weeks to a field-testable prototype
Budget Band
£30k–£45k (firmware + portal + enclosure)
Technical Constraints
- Offline-capable sync queue for up to 8 hours of disconnected operation
- ERP REST API integration (existing spec supplied)
- 1.5 m drop-rated enclosure, IP65
- Battery life ≥ 8 hours continuous active scanning
Our Approach
- 1
Fit check & constraints clarification
Reviewed ERP API documentation, confirmed UHF RFID module options, and validated enclosure drop-test approach.
- 2
Requirements & acceptance criteria for V1
Defined offline sync queue size, barcode read success rate target (≥ 98%), battery life test protocol.
- 3
Architecture & risk register
Selected NXP i.MX RT + Zebra UHF module. Risk flagged on import lead times; BOM alternates identified.
- 4
Design & build across disciplines
Concurrent: firmware development, enclosure CAD with drop-test ribs, and web portal build.
- 5
Integration & validation
ERP integration tested with a staging environment; offline sync stress-tested across 8 simulated hours.
- 6
Handover package
Full repository, enclosure STEP files, portal deployment guide, and recorded handover session.
What We Delivered
- BOM and integration schematic for selected module stack
- Interface documentation for RFID and barcode peripherals
- Revision notes from costing review
- NXP i.MX RT firmware source (bare-metal + FreeRTOS tasks)
- Offline sync queue implementation with conflict resolution
- Flash and debug guide; diagnostics screen documentation
- Pistol-grip enclosure CAD (SolidWorks + STEP + drawings)
- Drop-test rib analysis and assembly notes
- DFM notes; vendor short-list for injection moulding
- React web portal (full source repo)
- Node.js REST API and ERP bridge service
- Deployment guide and admin documentation
Outcome
"V1 prototype completed within the 10-week window. Field testing across two warehouse sites confirmed the offline sync queue handled 7.5 hours without data loss. The SME proceeded to an order for 25 production units."
Handover
- Firmware, portal, and hardware repos delivered
- Enclosure manufacturing pack and vendor contacts
- ERP integration runbook
- Handover call and recorded session
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