Amazon Smart Warehouse Locker

Lost, uncharged, and untracked barcode scanners disrupt warehouse efficiency

In Amazon's vast warehouses, barcode scanners are critical tools for employees, enabling smooth and efficient workflows. However, the scale of Amazon's operations magnified issues with lost, stolen, or dead scanners, creating both logistical challenges and financial losses. Without a check-in/check-out system, scanners were simply laid out on tables, making it difficult to track which employees were using which devices. Moreover, employees frequently picked up scanners with insufficient battery life, disrupting operations and causing inefficiencies.

Amazon needed a solution that provided a chain of custody for scanners, ensuring management could track equipment usage while guaranteeing employees access to fully charged devices. The goal was to develop an intelligent locker system that allowed employees to scan their badges, check out a scanner, and ensure the device was ready for use.

Iterative Development for to create a scalable, future-proof system

Project Phase 1: Refining the Existing Product

Amazon initially came to us with an early version of the product. Our first task was to reverse-engineer the CAD from the existing physical product to make the necessary design updates. On the firmware side, we began with a code review to diagnose and fix several critical bugs causing the system to reset frequently. Using the existing PCB design, we identified firmware issues and implemented fixes to stabilize performance.

Due to our location in Nashville, we conducted onsite testing at Amazon warehouses, which was instrumental in ensuring the product worked reliably in real-world conditions. This hands-on approach allowed us to validate our firmware fixes directly in the field.

Project Phase 2: Expanding Capabilities for the Next Generation

Amazon required additional functionality and cost optimizations for the next generation of lockers. We mechanically reengineered the locker and charging trays to make them more modular, allowing them to accommodate various types of barcode scanners, including handheld mobile computers, pistol grip scanners, and wearable ring scanners—each commonly used in Amazon's warehouse operations. This adaptability ensured the system could support a broader range of devices while maintaining efficiency. We updated the hardware design to support new features, including:

• Over-the-Air Updates (OTA): Enabled remote firmware updates and diagnostics using our partner, Memfault, to monitor device performance in the field.
• Remote Logging and Analytics: Provided detailed metrics and insights into device usage and performance.
• Improved Charging Capabilities: Developed smart charging functionality to optimize power distribution and ensure scanners were fully charged.
• RFID Integration: Added RFID to each charger for precise tracking of devices.

Our manufacturing and import teams also researched device classifications and developed a strategy to help drastically reduce import costs, optimizing the financial feasibility of large-scale deployment. Additionally, we provided architecture planning to future-proof the system, enabling it to adapt to new scenarios, such as increased locker capacity or modified dimensions. Our adaptable system design ensured that Amazon's lockers could evolve alongside their operational needs.‍

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Enhanced traceability and efficiency for Amazon warehouses

The final product is a smart locker system that provides access control and inventory management for barcode scanners. Employees scan their badges to access the locker, which opens the correct door and indicates which scanner to use based on charge level. Key features include:

• Chain of Custody: Clear traceability of which employee checked out which device, improving accountability.
• Smart Charging: Optimized charging capabilities to maximize the availability of fully charged scanners.
• Scalability: Lockers designed for configurations of 2-10 units tailored to warehouse needs.

Amazon deployed an initial batch of 60 lockers, with nationwide installation underway. The system ensures employees have reliable access to fully charged devices while providing management with the tools to track and maintain equipment effectively.

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