Case Study · E-commerce
E-commerce Fulfilment
Pick-to-cart AGVs and vision-based put-wall sorting up to 1,200 orders/h — absorbing peak-season spikes without overtime.
1,200
Orders / hour
99.9%
Pick accuracy
35%
Cost / order
30k
Orders / day
The Challenge
Order spikes and pick errors
A 3PL e-commerce warehouse handling 30,000 orders/day struggled to keep pace with volatile demand:
- ▸Peak-season orders spiked 3-4x, requiring costly overtime and temporary labor.
- ▸Manual put-wall sorting produced pick errors that triggered returns and SLA penalties.
- ▸Long pick paths and dwell times limited throughput to under 600 orders/h.
The Solution
Pick-to-cart automation, wave by wave
We deployed a vision-driven fulfilment cell integrated directly with the WMS:
- ▸Pick-to-cart AGV fleet that brings goods-to-person picking in optimized waves.
- ▸Vision-based put-wall with AI barcode/OCR verification on every slot.
- ▸WMS wave integration for real-time order routing and peak-season scaling.
How it was delivered
Flow audit
Two-week analysis of pick paths, put-wall dwell times and order-wave profiles for a 12,000 m² site.
System design
Pick-to-cart AGV fleet + vision-based put-wall with WMS wave integration.
Go-live
Commissioned in 10 weeks during a peak ramp, with live order-wave routing.
Scale-out
Fleet grown to 24 AGVs and put-wall lanes expanded for peak season.
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