9 shuttles. 190 lanes. One consolidated facility.
A consumer products distribution operation needed to absorb the volume of a second facility into a single building — without expanding the footprint or compromising shipping accuracy. We designed the deep-lane storage layout, built the WMS-to-shuttle middleware service, and ran phased commissioning across five aisles.
The result: 100+ pallets per aisle (a >12× density gain over the previous double-deep selective rack), strict FIFO enforcement, and three integration services running with zero service-level errors at observation time.
Predictive maintenance reduces unplanned downtime by 64%
Sensor data from a multi-line manufacturing floor was streamed through a middleware service into a forecasting model — flagging bearing and motor failures weeks in advance.
SAP-to-PLC bridge ships in 11 weeks
Replaced a brittle decade-old integration between SAP and shop-floor PLCs with a modern middleware service. Bidirectional data flow, full health monitoring, and zero-downtime cutover.
Real-time KPI portal replaces three legacy dashboards
A 3PL operation had three different dashboards across three different vendors — none of them current. We consolidated everything into a single live SQL-backed portal that supervisors check 100+ times per shift.
Vision-based label QA catches defects at line speed
Camera-based inspection at end-of-line replaces manual sampling. Surface defects, label-print accuracy, and packaging integrity all checked in real time — at 240 units/minute.