Sample count automation, human error, and database utilization. How to save money by automating and integrating your counting scales with an inventory management system. By Austin Helton

Weighbox from Genweigh, LLC

Counting scales have long been a clever way to save time when counting units. For decades, small and large businesses have been using counting scales. A well made and well calibrated counting scale is a valuable, time saving device that is faster and more accurate than hand counting widgets.

It appears this commonplace improved output has been adequate for a large percentage of the scale industry and the customers who use these scales. When one is deciding whether or not to hand count a shipment of units, the counting scale is an obvious choice. Few would argue with the value that a quality counting scale can add to pack-and-ship operations. BUT, can the standard process be improved? We believe it can be improved dramatically.

Standard practice for using a counting scale, regardless of make or model, is to first and foremost prep the scale to count specific widgets by conducting a sample count. A sample count is a logical and common sense way to let the scale know what an individual unit weighs, so it can quickly and accurately count more than 1 unit. Conduct a sample count of something like 10 units and then the scale will count the batch. Easy. Some counting scales can even be programmed to remember piece weight, but often times this is limited to SKU count, and creates another layer of potential human error when trying to pull back the stored piece weight.

Regardless of make and model, or how regular your human error exists in operation, an incredible amount of time is still spent on pre-programming counting scales, performing sample counts, and re-performing sample counts. Often times, this takes longer than that actual counting! What if there was a way to automate this process? What if there was a way to never sample count again! What if the counting scale became an integral, seamless cornerstone inside the pack-and-ship operation. It is a logical place for the work to be done, but it is absurd how much time we spend prepping each and every count. Especially when so many pack-and-ship operations spend so much money on enterprise level ERP solutions, inventory databases, and workflow solutions. How much money is spent on wasted labor hours, packer error, time in and out of different software solutions, etc. There is an obvious and real need for a software solution to tie this process together. Eliminate error. Eliminate redundant sample counts. Store piece weight for automated retrieval in the tens of thousands of SKUs and beyond. Use the counting process to correct inventory levels. Integrate the scale with pick-ticket software. There are countless ways that the "count-pack-and-ship" process needs to be improved; to save time, money and accuracy.

We have built a solution.

Genweigh has developed a cross platform mobile solution that allows a MADE IN USA counting scale to be mirrored through an iphone, android, pc, tablet, etc. allowing the scale to communicate wirelessly to an internal inventory management database, and more.

Effectively giving the scale the brains of a fully functional computer, the pack-and-ship process is now capable of pulling piece weights from a database, reading and writing to replace inventory levels, recording and monitoring rolling average piece weights per SKU, tracking lot ID weights and variance, integrating barcode scanners, QR codes, seamlessly and entirely tying together your workflow. We have this solution in practice, deployed in real industry applications; and it is saving labor, time, eliminating points of human error, integrating various 3 rd party workflow solutions and doing all of it through a modern, sleek, easy to use touch screen interface.

How much? NOT an arm, nor a leg.

With same year payback and single year positive ROI with even modest order volumes, we have run calculations that this solution will save small business owners as much as $32,000 in labor time through sample count elimination ALONE!

The WEIGHBOX is a revolutionary solution that can be customized to your specific workflow, and will save you or your customers thousands of dollars in year 1, 2, 3, and for the life of its deployment.

Do you or your customers have a QR code pick ticket system?

Do you have an inventory management system in place?

Do you use a counting scale to pack and ship widgets?

Let Genweigh show you how the WEIGHBOX can save you time, money, error, and headache.


We are proud to have developed a custom solution that we tailor to your database / environment that is perfect for inventory management and pack & ship applications. We have developed this solution with a Pennsylvania Scale 7600 DB, custom developed software (SQL server compatible), custom hardware with wifi signal, all integrated in a seamless package which communicates wirelessly with your network via user interface on iPad, iPhone, Android, PC, etc.

This was initially developed for the Epicor Prophet 21 (P21) inventory management system.

Package includes:

Weighbox Database communication software (tailored to your network)

Pennsylvania 7600-10DB with 100 lb dual base

Genweigh Weighbox hardware (installed)

Customized user interface (web-based)

Customized and implemented to your specific database!


The Weighbox is a product that augments an industrial scale to provide customized remote access and system integration capabilities. This allows the scale to be more than just a measuring device, but a complete part of the industrial process. In particular, the delivered Weighbox will integrate with your SQL server based inventory management system to allow counting of stock items by part number. This streamlines the counting process and eliminates both a source of human error, and the necessity of a sample count procedure once the piece weight is known in DB.


The Weighbox shall provide an HTTP REST API for configuring scale parameters. The Weighbox shall provide an HTTP REST API for accessing scale configuration parameters. The Weighbox shall provide an HTTP REST API for accessing scale measurement / count values. The Weighbox shall serve an HTML/CSS/Javascript GUI over the network. The Weighbox shall provide a GUI compatible with web browsers for the following devices: Windows 7 PC (Chrome), iPad (Safari), iPod (Safari). The Weighbox shall be able to display the following scale values at all times: status, gross weight, tare weight, net weight. The Weighbox shall be able to display the following values when a part weight has been selected: part count. The Weighbox shall allow manual entry of a part weight. The Weighbox shall allow text entry of a part number for querying. The Weighbox shall fetch and display the following information from the database given a part number: name, weight. The Weighbox shall support display and input of weights in the following units: pounds, ounces, kilograms, grams. The Weighbox shall allow the user to zero the scale.

Performance Requirements The Weighbox shall be capable of serving a minimum of 3 simultaneous network clients. The Weighbox shall support a data refresh rate of no less than 1 update per second per client. The Weghbox shall be able to perform a minimum of 1 query per second against the database.

Interface Requirements The Weighbox shall connect to the database over an Ethernet connection. The Weighbox shall be assigned a fixed IP address for use on the network. The Weighbox shall connect to the database using username and password credentials. The Weighbox shall not require credentials which allow writing to the the database. The Weighbox shall not require any modification to database beyond creating a read-only account for queries.

Security Requirements The Weighbox shall allow HTTP access to any user or device on the network. The Weighbox shall be accessible via SSH username/password for maintenance and upgrades. Physical Requirements The Weighbox shall be powered from a single 110V AC electrical outlet. The Weighbox shall connect to an Ethernet network via CAT5e or higher cabling.