A long-established European distributor of professional tools and industrial supplies, serving 20,000+ customers.
Automated Packaging & Material Flow: Boosting Efficiency in Tools Distribution
The Challenge
Manual wedging, lidding and labelling made packaging slow and inconsistent, and without automated weight and fill control there was packaging waste and quality issues. WMS and WCS needed to work closely together for delivery-note printing and labelling, and high shipment volumes demanded reliable throughput and uptime.
What We Did
We extended the warehouse- and material-flow-control system to run new conveyors, strapping and labelling zones, added 3D camera-based fill control that automatically ejects underfilled cartons, and automated invoice and label insertion. Dynamic ejection logic handles errors and routes intelligently, automated weight verification and strapping protect packaging integrity, and real-time monitoring tracks throughput and errors across 50+ conveyor branches.
The Impact
How We Delivered
A senior, Europe-based four-person team - a project manager, a lead software engineer, a software engineer and an IT logistics consultant - delivered over 12 months. Each shipping antenna was commissioned in sequence to avoid production downtime, managed through a structured Waterfall process with defined delivery phases. Conveyor logic and weight validation were simulated and tested before go-live, print, label and ejection processes were fully verified at final acceptance, and IT, controls and operations worked together to keep the system stable - with user training and documentation for independent operation and maintenance.
Inside The Build
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