LoRaWAN People Counter
Macnman Technologies partnered with Amazon’s warehouse management team to deploy a LoRaWAN-based People Counter for real-time space utilization and workforce movement tracking. Using our MacRay ToF sensor, the system accurately detects human movement at entry and exit points — without capturing personal data — ensuring privacy, scalability, and high accuracy.
The LoRaWAN network transmits occupancy data securely to Amazon’s central server, enabling data-driven space planning, optimized workforce deployment, and improved energy efficiency. This solution demonstrated how IoT and LoRaWAN can transform warehouse operations with minimal infrastructure changes.
The Challenge: Blind Spots in Warehouse Space Usage
Even with advanced warehouse operations, Amazon faced challenges in tracking real-time space and workforce utilization , The goal was clear — implement a LoRaWAN People Counting system to provide real-time, zone-specific insights, enabling smart space utilization and optimized warehouse operations.
Limited Visibility
Traditional methods couldn’t provide accurate, real-time occupancy data for every zone.
Inefficient Space Management
Some areas were overcrowded while others remained underused, reducing operational efficiency.
Manual Tracking
Staff had to physically monitor foot traffic, increasing labor costs and errors.
Delayed Decision-Making
Lack of instant data caused slow adjustments in workforce deployment and storage allocation.
Proposed Solution: Smarter Space Insights with LoRaWAN People Counter
To address the warehouse visibility gap, we deployed a LoRaWAN-based people counting and space utilization system using Macnman’s MacRay Series sensors.
- 01
LoRaWAN People Counter Integration
Installed MacRay LoRaWAN People Counters at strategic entry and exit points to track real-time movement and occupancy trends.
- 02
Zone-Wise Data Mapping
Each counter node transmitted occupancy data via LoRaWAN gateways, enabling zone-level analytics without relying on Wi-Fi or wired networks.
- 03
Smart Dashboard Connectivity
All data was fed to a central dashboard for live monitoring, space usage trends, and automated report generation.
- 04
Threshold Alerts for Optimization
Intelligent thresholds were configured to trigger alerts when zones reached critical occupancy levels, allowing dynamic workforce reallocation.
- 05
Minimal Infrastructure, Maximum Coverage
The low-power, long-range LoRaWAN network required minimal setup, perfectly suiting the massive warehouse layout.
- 06
Seamless SCADA Integration
Data was made compatible with the existing Amazon warehouse management system (SCADA) for smooth visualization and control.
LoRaWAN Architecture for Green-house Automation
Deployment: LoRaWAN People Counters for Smart Warehouse Monitoring
The deployment focused on real-time occupancy tracking and space utilization monitoring without disrupting Amazon’s warehouse operations
MacRay LoRaWAN People Counters
Installed at entry, exit, and high-traffic zones to provide accurate footfall and occupancy data.
Industrial LoRaWAN Gateway
Aggregated data from multiple counters and forwarded it to the central monitoring dashboard.
SCADA System Integration
Enabled real-time occupancy insights, zone-level utilization trends, and historical analytics for informed decision-making.
Local Indicators
Additional Indicators for the visual notifications for alerts in case of the unsafe environments conditions.
Deployment Challenges: Ensuring Accuracy and Coverage ⚡
High Traffic Interference
Movement of forklifts, pallets, and staff caused potential detection errors, requiring strategic sensor placement.
Long-Range Connectivity
Ensuring LoRaWAN nodes transmitted data reliably across the large warehouse without dead zones.
Integration with Existing Systems
Seamless data flow to Amazon’s SCADA/dashboard required precise configuration of MacSet nodes and gateways
Environmental Obstacles
Metal racks, storage containers, and high ceilings impacted signal strength, mitigated with gateway positioning and signal calibration
Impact: Real-Time Space Optimization & Operational Efficiency 🚀
Accurate Occupancy Tracking
Real-time data on entry, exit, and zone occupancy improved workforce planning.
Optimized Space Utilization
Identified underused and overcrowded areas, enabling efficient storage and layout adjustments.
Energy Savings
Insights allowed HVAC and lighting optimization based on actual occupancy, reducing energy costs.
Data-Driven Decisions
Historical and live analytics provided actionable insights for warehouse management.
Validation & Testing: Ensuring Accuracy and Reliability ✅
Footfall Accuracy Checks
Verified MacRay people counters against manual counts, achieving >95% accuracy in detecting personnel movement
Real-Time Data Verification
Ensured all LoRaWAN nodes transmitted consistent occupancy data to the central dashboard without delays.
SCADA Integration Testing
Data flows were validated to ensure seamless integration with Amazon’s warehouse management dashboard.
Long-Range Connectivity Tests
Confirmed reliable LoRaWAN communication across the entire warehouse, even with metal racks and high ceilings.
Conclusion: Smarter Warehouses with LoRaWAN People Counters 🚀
The deployment of MacRay LoRaWAN People Counters in Amazon’s warehouse showcased how real-time occupancy monitoring can transform large-scale operations. By providing accurate footfall data, zone-level space insights, and seamless SCADA integration, the system enabled optimized space utilization, energy savings, and operational efficiency.
This project demonstrates the power of IoT and LoRaWAN technology in creating smart, data-driven warehouse environments without requiring major infrastructure changes
Ready to Optimize Your Warehouse? 🚀
