International Research Journal of Innovations in Engineering and Technology - IRJIET International Open Access, Monthly, Peer Reviewed, Reputed Journal ISSN (online): 2581-3048

Impact Factor (2025): 6.9

DOI Prefix: 10.47001/IRJIET

Optimized Warehouse Management System Leveraging Industry 4.0 Technologies

A.A.A.S. AbeydeeraFaculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri LankaP.D.M.P. PalihenaFaculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri LankaP.A.S. TharanaFaculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri LankaV.S.D. AmangilihewaFaculty of Computing, Sri Lanka Institute of Information Technology, Malabe, Sri LankaDinuka WijendraDepartment of Information Technology, Sri Lanka Institute of Information Technology, Malabe, Sri LankaProf. Samantha RajapakshaDepartment of Information Technology, Sri Lanka Institute of Information Technology, Malabe, Sri Lanka

Vol 9 No 10 (2025): Volume 9, Issue 10, October 2025 | Pages: 174-181

International Research Journal of Innovations in Engineering and Technology

OPEN ACCESS | Research Article | Published Date: 05-11-2025

doi Logo doi.org/10.47001/IRJIET/2025.910024

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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.

Keywords

Smart warehousing, TSP, A* pathfinding, YOLOv8 fire detection, ARIMA, Prophet, LSTM, worker analytics, Best-Fit bin-packing, 3D visualization, Industry 4.0


Citation of this Article

A.A.A.S. Abeydeera, P.D.M.P. Palihena, P.A.S. Tharana, V.S.D. Amangilihewa, Dinuka Wijendra, & Prof. Samantha Rajapaksha. (2025). Optimized Warehouse Management System Leveraging Industry 4.0 Technologies. International Research Journal of Innovations in Engineering and Technology - IRJIET, 9(10), 174-181. Article DOI https://doi.org/10.47001/IRJIET/2025.910024

Licence Copyright (c) 2026 International Research Journal of Innovations in Engineering and Technology creative common licence This work is licensed under Creative common Attribution Non Commercial 4.0 Internation Licence
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