GPS-Enabled Tracking System for Returnable Skids & Industrial Packaging Logistics

Industry: Industrial Packaging, Heavy Engineering, Automotive Supply Chain

Region: India, Europe, Southeast Asia

Engagement: Hardware + IoT platform development for real-time tracking of returnable skids used for transporting heavy auto components across multiple manufacturing and export locations.

Technology Stack Overview

IoT Hardware:Custom GPS module, 4G/LTE communication, long-life lithium battery module, IP67 rugged enclosure, tamper sensors

IoT Backend:AWS IoT Core, MQTT, AWS Lambda, DynamoDB, S3, CloudWatch

Software & Dashboard:

• Web App: ReactJS

• Backend: Python (FastAPI), Node.js

• Mapping: Mapbox / Google Maps API

• Inventory Engine: TimescaleDB for location history and skid cycle analytics

Security:Encrypted telemetry, device-level certificates, IAM-based access

Challenge

The client manufactured returnable metal skids used to transport heavy automotive components between:

• Supplier plants

• OEM factories

• Export hubs

• Warehouses

• Global logistics partners

However, they faced major operational challenges:

• Skids frequently went missing across warehouses and transport lanes

• No real-time visibility into skid location or movement

• Manual audits caused errors and delays

• Cycle time from “dispatch → return” could not be measured

• Missing skids led to significant financial loss and disruption in exports

• Battery-powered tracking was essential due to absence of power at skid locations

The client needed a rugged, battery-operated IoT tracking system with a centralized platform to track each skid’s location, movement, and lifecycle.

Solution

EC Infosolutions engineered a GPS + IoT tracking ecosystem specifically designed for industrial returnable packaging - combining hardware durability with cloud intelligence.

Key Functional Modules

1. Rugged GPS Tracker for Skids

Developed custom hardware engineered for industrial conditions:

• Long-life battery unit

• Magnetic & bolt-on mounting options

• IP67 water/dust protection

• GPS + 4G/LTE data uplink

• Motion detection & tamper alert sensors

• Periodic “heartbeat” pings to preserve battery life

The device transmitted telemetry securely to AWS IoT Core.

2. AWS IoT Backend for Real-Time Monitoring

The cloud architecture included:

• AWS IoT Core for secure device connectivity

• Lambda functions for geofencing, event processing & battery analytics

• DynamoDB for low-latency storage

• TimescaleDB for movement history and cycle time analytics

• CloudWatch alerts for battery low, abnormal movement, or idle skids

3. Web Dashboard for Inventory & Location Tracking

A powerful ReactJS-based dashboard gave operations full visibility:

• Real-time GPS location on a map

• Skid counts by location (plant, warehouse, transit, OEM)

• Geofence rules for inbound/outbound detection

• Movement history playback

• Cycle time analysis (dispatch → return)

• Idle skid alerts

• Stolen/missing skid tracking

• Exportable audit reports for logistics partners

4. Skid Inventory Management System

Software classified each skid by:

• Unique ID / QR code

• Current location

• Last movement timestamp

• Condition & maintenance cycle

• Usage count

• Customer, shipment or batch linkage

This enabled SKU-level visibility, just like tracking high-value assets.

5. Mobile App for Field Operators

Optional mobile version enabled:

• QR code scanning of skids

• Manual updates when GPS signal was low indoors

• Movement confirmation

• Maintenance checks

• Offline mode with sync

Results

• Asset Loss Reduced: Missing skid incidents dropped by 70–80% through GPS visibility.

• Operational Efficiency: Reduced manual audits and saved thousands of man-hours annually.

• Improved Cycle Time: Data-driven insights optimized skid rotation, improving logistics throughput.

• Financial Savings: Prevented frequent re-manufacturing of lost skids, saving significant capex.

• Predictive Movement: Geofenced alerts enabled planning for incoming/outgoing shipments.

• Scalability: Solution deployed across multiple plants, logistics centers & export hubs.

Key Takeaways

• IoT-powered tracking brings real-time transparency to industrial packaging logistics.

• Battery-powered GPS modules extend tracking capabilities to remote areas without power.

• A unified dashboard enhances fleet utilization and reduces asset loss substantially.

• Predictive analytics improves supply chain flow and reduces downtime at OEMs.

• This framework can be extended to pallets, containers, cages, racks, crates, and reusable packaging.

Get Connect

Looking to modernize your industrial logistics with real-time IoT visibility?

At EC Infosolutions, we help manufacturers and supply chain leaders build rugged, scalable hardware plus cloud platforms that unlock asset intelligence across plants, warehouses, and global transit routes.

Contact us to explore how IoT tracking can transform your returnable packaging and supply chain operations.