AI is playing an increasingly transformative role in inventory tracking and operational efficiency by enabling intelligent automation and predictive analytics.
Artificial intelligence (AI) and the Internet of Things (IoT) are driving a new wave of efficiency across industries, including physical security.
As organizations look to improve operational visibility, enhance asset management, and streamline workflows, these technologies are setting new standards in automation and real-time decision-making.
For system integrators and consultants in the security sector, the implications extend beyond manufacturing, offering lessons in how data-driven intelligence can be applied to surveillance, access control, and integrated security management.
According to Aik-Jin Tan, APAC Marketing Leader for Manufacturing and Singapore ZEC at Zebra Technologies, AI is emerging as a key enabler of smarter operations.
“AI is playing an increasingly transformative role in inventory tracking and operational efficiency by enabling intelligent automation and predictive analytics,” Tan said. He explained that AI-powered systems are no longer confined to static monitoring. Instead, they leverage streams of data from IoT devices to provide actionable intelligence in real time.
AI’s growing role in operational efficiency
Tan highlighted several ways in which AI is expanding its influence on inventory and resource management.
“Zebra’s AI-powered solutions leverage data from IoT devices to enhance asset visibility, forecast demand, and optimize resource allocation,” he said.
This evolution of AI allows organizations to move from a reactive posture to a proactive one, anticipating issues before they escalate.
Predictive analytics for proactive inventory management
For example, predictive algorithms can scan inventory data to identify patterns that point to upcoming shortages or surpluses. By flagging these potential risks early, AI systems can recommend corrective actions.
“AI algorithms can predict potential stock shortages or overstock scenarios and recommend corrective actions, ensuring inventory levels remain balanced,” Tan explained.
This capability is relevant for physical security professionals who often face similar challenges in maintaining balanced hardware inventories. Whether it involves ensuring sufficient stock of cameras, access control panels, or replacement parts, the ability to anticipate demand can reduce downtime for installations and minimize supply chain disruptions.
How AI streamlines compliance and frontline support
AI’s role also extends to compliance and frontline support. “Additionally, AI empowers the connected frontline by automating compliance checks and streamlining workflows, providing actionable insights in real-time,” Tan noted.
By automating compliance, organizations can minimize errors while freeing up staff to focus on more strategic tasks.
Tan added that AI’s trajectory is far from complete. “As AI continues to evolve, its role will expand into autonomous decision-making and dynamic process optimization, setting new benchmarks for operational efficiency and business agility,” he said.
For integrators, this trend suggests future security systems may not only monitor environments but also autonomously adapt responses based on evolving risks.
IoT deployment example highlights real-time visibility
AI’s value is amplified when paired with IoT technologies that collect and transmit real-time data. Tan described a deployment that illustrates this synergy. “A recent deployment at a large-scale manufacturing facility showcases the transformative impact of IoT on asset visibility and operational workflows,” he said.
The client in question was struggling to track raw materials and finished goods across multiple production lines. The lack of real-time visibility created bottlenecks in locating assets and verifying stock levels.
To address these issues, an IoT-based system was introduced. “Zebra implemented an IoT solution featuring RFID tags, handheld readers, and fixed asset tracking systems integrated with the client’s ERP platform,” Tan explained.
Automation improves workflows and delivery timelines
The integration provided immediate visibility into asset movement across the facility. Materials could be located quickly, while inventory accuracy improved significantly. For the frontline workforce, this meant less time spent searching for assets and more time dedicated to value-added tasks.
The deployment also highlighted the role of intelligent automation. “This solution provided real-time asset visibility, enabling the client to locate materials and inventory efficiently while ensuring accurate tracking throughout the production process. Intelligent automation further enhanced workflows by enabling automated reordering triggers and compliance monitoring, simplifying operations and improving overall efficiency,” Tan said.
The result was a more streamlined operation that improved delivery timelines and customer satisfaction.
As Tan summarized, “This deployment empowered the connected frontline, streamlined operations, and contributed to better delivery timelines and customer satisfaction.”
What security professionals can learn from manufacturing
Although the case study originates from manufacturing, the parallels with physical security are clear.
In modern security operations, visibility and efficiency are equally critical. Integrators deploying video surveillance or access control solutions face growing demands from customers to not only secure assets but also improve operational workflows.
The use of RFID and IoT sensors in the manufacturing example offers insights into how similar technology could be applied in secure facilities.
RFID-enabled access and anomaly detection
For instance, RFID-enabled access systems can provide granular visibility into personnel movement, while IoT sensors can deliver real-time alerts on anomalies such as unauthorized access or tampering with security hardware.
Enterprise integration for situational awareness
The integration with enterprise platforms is another key takeaway. By linking IoT-based asset visibility tools with ERP systems, the manufacturing client ensured data consistency across workflows. In the security sector, similar integration with building management or enterprise IT platforms can enhance situational awareness and improve coordination between security and operational teams.
Predictive analytics applied to surveillance and access control
The predictive nature of AI-driven analytics in inventory management also has direct relevance for security. Just as algorithms can forecast shortages, they can also detect unusual patterns in surveillance data or access logs.
By identifying risks before they escalate, AI allows security teams to act preemptively rather than reactively.
Autonomous decision-making as the next frontier
Moreover, the concept of autonomous decision-making, which Tan identified as the next step in AI’s evolution, could transform the way security systems respond to incidents.
Future systems may be able to autonomously escalate alerts, lock down facilities, or adjust surveillance coverage without human intervention, increasing both speed and precision in crisis response.
Empowering the connected frontline in security operations
The idea of empowering the connected frontline resonates strongly in the security industry, where guards, operators, and system users rely on actionable intelligence to make quick decisions.
Automating compliance checks, as described in the manufacturing deployment, mirrors the need for automated auditing in security environments.
For example, automated systems can ensure that access rights remain current or that surveillance systems adhere to regulatory standards.
Integration with enterprise platforms enhances efficiency
Tan’s emphasis on streamlining workflows highlights another area of overlap. In security operations centers (SOCs), workflow efficiency is essential.
AI and IoT-driven platforms can reduce manual monitoring by flagging only the most relevant events, helping operators focus on priorities and reducing the risk of oversight.
Integration with enterprise IT or building management platforms can further expand visibility and improve coordination across departments.
The future of AI and IoT in security environments
The deployment of AI and IoT in manufacturing offers a glimpse into the future of operational efficiency across industries, including physical security. The technology is shifting the focus from manual processes to intelligent, data-driven systems that adapt dynamically to changing conditions.
For integrators and consultants, these developments underscore the importance of adopting a broader perspective when designing security solutions. By learning from use cases in adjacent industries, security professionals can anticipate customer needs for real-time visibility, predictive insights, and autonomous operations.
Tan concluded that AI and IoT are poised to redefine operational standards. “As AI continues to evolve, its role will expand into autonomous decision-making and dynamic process optimization, setting new benchmarks for operational efficiency and business agility,” he said. This vision suggests that future security environments will not only safeguard assets but also enhance the efficiency and resilience of entire organizations.