Maintenance & Reliability · SOP

Warehouse Drone Inventory Scanning Safe Operation Setup

This procedure defines the mandatory steps to safely deploy an autonomous drone for warehouse inventory scanning. It covers pre-flight inspections, flight path validation, personnel exclusion, and emergency recovery procedures.

Estimated Time

30 min

Difficulty

Intermediate

Regulation

CSA Z432

Version

1.0

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Purpose

To establish a repeatable safe procedure for operating an unmanned aerial vehicle (drone) for autonomous inventory scanning inside a warehouse environment. This SOP minimizes risk of collision, personal injury, and equipment damage while maximizing scanning accuracy.

Scope

This SOP applies to all shifts operating DJI Matrice 300 RTK (or equivalent) drones equipped with Livox Mid-40 LiDAR and a high-resolution camera for inventory barcode scanning. It covers pre-flight checks, flight zone preparation, autonomous mission execution, and post-flight data handling. Excluded are outdoor flights and manual piloting beyond the designated ROI.

Safety Precautions

LOTOLockout/Tagout all overhead conveyors and automated retrieval systems in the scan zone before drone deployment.
PPEAll personnel within 15 m of the flight zone must wear hard hats, safety glasses, and high-visibility vests.
RFRadio frequency interference: Confirm no active welding equipment or high-power transmitters are operating within 50 m of the drone controller.
BATOnly use manufacturer-approved batteries. Inspect for swelling, leaks, or damage before installation.

Required Tools & Materials

Autonomous drone (DJI Matrice 300 RTK or equivalent) with LiDAR / camera module
Drone controller tablet (iOS or Android) with FlightHub / DJI Pilot 2 software
Warehouse floor plan (CAD or BIM) for path planning
Safety cones, tape, and warning signage (minimum 4 sets)
Personal protective equipment: hard hat, safety glasses, high-vis vest
Battery charging station and spare batteries
Data transfer cable or SD card reader
Pre-flight checklist (printed or digital)

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Procedure: Step-by-Step

1 Perform pre-flight safety inspection — Visually inspect drone frame, propellers, sensors, and battery for damage or debris. Verify all firmware is current. Confirm GPS lock and compass calibration on the controller.

2 Clear and mark the flight zone — Remove personnel and obstructions from the designated scan area. Deploy safety cones and warning signage at all entry points. Establish a no-entry perimeter of 3 m around the flight path.

3 Upload and validate flight path — Import warehouse floor plan into flight control software. Define altitude (2.5 m above tallest rack), obstacle avoidance zones, and return-to-home coordinates. Simulate the path to confirm no collisions.

4 Conduct system arming check — From the controller, verify battery voltage (≥24 V), GPS fix (≥10 satellites), and remote signal strength. Arm motors only after confirming all personnel are outside the perimeter.

5 Execute automated inventory scanning — Engage autonomous scan mission. Monitor telemetry (battery, altitude, signal strength) continuously. Keep hands near the emergency stop. If telemetry shows any anomaly, immediately abort.

6 Perform post-flight landing and data review — Allow drone to return to home and land. Disarm motors, remove battery, and download scan data to the central inventory system. Verify the data integrity by spot-checking a sample aisle. Complete the shift log.

Warehouse Drone Inventory Scanning Safe Operation Setup

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