Degree

Master of Science in Computer Science

Department

Department of Computer Science

School

School of Mathematics and Computer Science (SMCS)

Date of Submission

Fall 2025

Supervisor

Dr. Imran Khan, Assistant Professor, Department of Computer Science

Keywords

Warehouse Management System, Digital Twin prototype, Digital Shadow, IoT, ESP32, load cell, proximity sensing, inventory control, forecasting, stock movement, simulation

Abstract

Warehouse operations require accurate knowledge of what stock exists, where it is stored, how it moved, and what is likely to be required next. Many small and medium organizations still depend on spreadsheets, disconnected applications, or delayed manual updates, creating discrepancies between physical and recorded inventory. This project presents a web-based Warehouse Management System developed using PHP 7.4 and MySQL/MariaDB. The system integrates product and customer master data, multi-warehouse locations, purchase orders, partial goods receiving, sales invoices, location-level stock, movement logging, reporting, forecasting, IoT rack readings, and a warehouse visualization and simulation module.

The solution uses authenticated sessions, role-based access control, CSRF protection, prepared statements, and transactional stock updates. The IoT interface validates a registered device and API key, converts rack weight into product quantity, maintains live and historical readings, and records quantity changes. Forecasting combines recent demand, prior-year seasonality, longer-term averages, minimum stock, and on-hand quantity to generate purchase recommendations and stock-out warnings. The warehouse representation supports location tiles, historical replay, utilization analysis, and what-if simulation.

The project also includes an implemented physical smart-storage prototype built around a load cell, HX711 24-bit ADC/amplifier, ESP32 WiFi microcontroller, proximity sensing, regulated power, and a remote server connection. Physical product addition or removal changes the measured weight and presence state, the ESP32 processes the sensor signals, and the server updates the live digital representation, history, dashboards, forecasts, and simulation views. The combined artifact is therefore presented as a Digital Twin prototype because both the physical product and its synchronized digital representation are implemented. Under the strict data-flow taxonomy used in digital-twin literature, however, the current deployment remains a Digital Shadow at the actuation boundary because digital recommendations do not automatically command a WCS, PLC, robot, or other physical actuator. Testing covers software integrity, deterministic IoT calculations, physical-device integration paths, security review, functional scenarios, and scalability analysis.

Document Type

Restricted Access

Submission Type

Research Project

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