Video Security for Distribution Center Inventory Control: Case Study

Success stories from our clients are some of the most gratifying parts of what we do at Vulcan Security Systems. This case study shows how a modern IP video system paired with AI and 24/7 monitoring, can pay for itself fast while solving a customer service headache that could have cost a distribution center a large account.

Below, you’ll see how a single system helped a Birmingham distribution company quickly identify a missing shipment, correct the issue, and ultimately improve its inventory control process.

What Problem Was the Distribution Center Trying to Solve?

The client, a major Birmingham distribution company, needed better visibility across their warehouse, loading docks, parking areas, and vehicle entry/exit points. Their biggest concerns were:

• Inventory control
• Tracking vehicle movement
• Reducing operational blind spots
• Improving accountability inside the warehouse

At Vulcan, we always begin with an onsite walk-through to define the exact scope before installing anything. This keeps the project focused, prevents scope creep, and ensures the system is built around actual risk, not assumptions.

How Vulcan Approached the System Design

After the site analysis, the solution was straightforward:

• 5MP German-made Mobotix hemispheric cameras were mounted on warehouse ceilings for maximum 360° coverage.
• Tighter lenses and higher-detail cameras were installed at vehicle entrances and exits to capture plates, driver activity, and precise movement.
• Outdoor cameras covered the parking lot and dock areas for complete perimeter awareness.

This system gave the client both wide-area visibility and the detail they needed at choke points, without flooding the facility with unnecessary cameras.

The Case of the Missing Shipment

Fast-forward about six months.

During one of our proactive monthly system health checks (a core part of Vulcan’s service contract), the HR director mentioned a troubling incident:

“We had an entire truckload of material go missing. Completely unaccounted for.”

Before installing a high-end IP video system, this situation may have led to finger-pointing, wasted hours in meetings, and a frustrated customer waiting for answers.

But now they had time-stamped, high-resolution video to turn to.

How Time-Stamped Video Footage Saves the Day

Using warehouse camera footage, the manager reviewed the specific window where the pick sheet should have been processed.

The 360° Mobotix hemispheric camera captured the entire sequence clearly:

A disgruntled employee threw away the pick sheet for the full outbound order destined for south Alabama.

Once identified, the employee was disciplined, but more importantly, the company was able to:

• Immediately recreate the order
• Load it onto the next outbound truck
• Contact the customer proactively
• Avoid a damaged relationship and possible penalties

In other words, the system didn’t just solve a security issue, it solved a customer service problem.

The ROI: Cameras Paid for Themselves

The HR director shared the owner’s reaction after reviewing the footage:

“It looks like those new cameras just paid for themselves.”

And they were right.

Missed shipments cost real money: lost labor, wasted materials, overnight reshipping costs, and sometimes lost customers. In this case, the avoided cost was significantly higher than the investment in the camera system.

Because of the success at the Birmingham facility, this client is now rolling out Vulcan systems across six additional regional distribution centers.

What This Means for Distribution Centers in 2025

Inventory issues aren’t new, but the technologies to prevent them have dramatically improved:

• AI video analytics: Detect unauthorized behavior, unusual movements, tailgating, and workflow anomalies automatically.
• Higher-quality IP video: Deliver clearer detail in low light with wider coverage and a 10-year average lifespan.
• 24/7 health monitoring: Identify and resolve camera issues proactively before the client notices.
• Remote support: Perform most diagnostics and fixes without a site visit, reducing downtime and service costs.
• Better evidence: Provide time-stamped video that resolves inventory discrepancies, labor disputes, and customer claims quickly.

Let Vulcan Security Systems Help You Strengthen Inventory Control

If your warehouse or distribution center is dealing with:

• Missing shipments
• Inventory discrepancies
• Unauthorized employee behavior
• Poor visibility in loading dock or staging areas

A properly designed IP video system can help you catch issues early or prevent them entirely.

Vulcan specializes in IP video only, with AI-powered monitoring, remote support, and industrial-grade Mobotix hardware that performs reliably in demanding environments.