Manual inventory counts and paper pick lists caused 8% order error rate.
We built a warehouse management system with mobile barcode scanning, optimized pick routes, and real-time inventory sync across e-commerce channels — replacing paper-based workflows that caused an 8% error rate.
Client
An e-commerce fulfillment center...
Timeline
12 weeks
Team
2 engineers
Industry
Logistics
An e-commerce fulfillment center processed a high volume of orders daily using paper pick lists. Workers walked inefficient routes, items were frequently mispicked, and inventory counts drifted significantly from actual stock levels. Returns from wrong-item shipments were a constant problem.
Implemented barcode scanning for receiving, picking, and shipping verification
Built wave-based picking with optimized routes that group orders by warehouse zone
Created real-time inventory sync with Shopify, Amazon, and WooCommerce
Added quality control checkpoints at packing stations with scan verification
<1%
Error Rate
40%+
Faster Picking
99%+
Inventory Accuracy
12 wks
Delivered In
Order error rate dropped from 8% to under 1%
Picks per hour increased by 40%+ through route optimization
Inventory accuracy improved from 85% to over 99%
Returns due to wrong-item shipments virtually eliminated
“Our error rate was embarrassing. Eight percent of orders going out wrong means a lot of angry customers and expensive returns. Now it's under one percent and our team is faster too because they're not walking random routes through the warehouse.”
— Operations Manager, Fulfillment Center
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