Executive summary
Kaufman Trailers, a North American trailer manufacturer, needed a reliable way to count large tire shipments during unloading without relying on manual clickers. SMS Storetraffic implemented a wireless beam sensor counting solution tailored to their process. The system enabled automated counting during unloading and immediately identified a discrepancy of four tires in the first full shipment of 800+ units. The solution reduced manual labor requirements and delivered immediate return on investment in a warehouse receiving context.
Key results
- Identified a 4-tire discrepancy on the first shipment of 800+ tires
- Reduced manual counting labor from 1–2 dedicated counters per unloading process
- Replaced a ~2-hour manual counting process with automated tracking during unloading
- Improved count accuracy compared to prior dual-counter verification method (frequent mismatches)
Customer profile
- Company: Kaufman Trailers
- Industry: Manufacturing / Trailer production
- Region: North America
- Use case: Shipment verification for inbound tire deliveries
- Operational context: Container unloading with teams of up to 8 workers
What challenge did the customer face?
Kaufman Trailers needed an accurate way to verify tire quantities during shipment unloading to ensure supplier billing matched actual deliveries.
Their receiving process involved unloading large, heavy tires from containers while manually tracking counts. This step is critical because suppliers invoice based on shipped quantities. Any discrepancy directly affects cost control and inventory accuracy.
Why was the previous method insufficient?
Manual clicker counting during unloading produced inconsistent and unreliable results, even when multiple employees tracked counts.
Previously, one employee stood aside counting tires with a clicker while up to eight others unloaded. Because of speed, fatigue, and visibility constraints, counts were often inaccurate. In some cases, two people counted simultaneously and compared results afterward, yet totals rarely matched. This made it difficult to confidently verify supplier invoices.
What did SMS Storetraffic implement?
SMS Storetraffic implemented a wireless beam sensor counting solution configured to count tires as they passed a fixed detection point.
Although typically used for people counting, the same core technology, a break-beam sensor, was adapted for object counting in a warehouse environment. The system was selected for its simplicity, affordability, and ability to operate without complex setup, programming, or infrastructure changes.
How was the rollout handled?
The system was deployed using a simple physical setup aligned with the tire unloading workflow, enabling accurate counting without disrupting operations.
The customer mounted the wireless sensors on custom brackets positioned at floor level to ensure each tire triggered a single count. During unloading, tires were directed through a controlled alley between pallets, ensuring consistent detection. The setup required minimal installation effort and was validated through repeat testing before full use.
What changed after deployment?
The automated system provided consistent counts during unloading and immediately detected discrepancies in supplier shipments.
During the first full container unload of more than 800 tires, the system recorded a total that was four units lower than the supplier’s packing slip. This confirmed both the accuracy of the counting method and the presence of a billing discrepancy. In addition, the business no longer needed to assign one or two employees solely to counting, reducing labor costs and simplifying the receiving process.
What can similar retailers learn from this?
Simple sensor-based counting systems can replace manual verification tasks in high-volume operations, improving accuracy while reducing labor dependency.
This case shows that:
- Automated counting is not limited to retail foot traffic. It can apply to inventory and logistics workflows
- Low-complexity solutions can deliver measurable ROI quickly when aligned with a specific operational need
- Accurate, real-time counts can directly impact cost control by validating supplier invoices
Why this matters for similar retailers
For retailers and operators managing inbound goods, manual counting introduces avoidable risk and labor overhead. This case demonstrates that a lightweight traffic intelligence solution from SMS Storetraffic can be adapted beyond store environments to automate verification tasks, improve accuracy, and uncover discrepancies early in the process.
