01
6–10 weeks

Discovery & Design

Site survey, throughput analysis, stakeholder workshops, integration architecture. We end this phase with a Business Requirements Document and a validated cost case.

[ Deliverables ]
  • On-site survey & operational walkthrough
  • Throughput, SKU, and inventory profile analysis
  • Lane / system / integration architecture design
  • Business Requirements Document (BRD)
  • Detailed cost case with ROI and payback period
▸ Stage Gate 01
Design freeze and signed business case before any procurement.
02
12–20 weeks

Procurement & Civil Works

Long-lead hardware procurement, floor preparation, electrical and network infrastructure, racking installation. The phase where the building physically transforms.

[ Deliverables ]
  • Vendor selection and PO management
  • Floor prep, electrical, and network infrastructure
  • Racking installation and certification
  • Charging station and communications hardware
  • Site readiness inspection
▸ Stage Gate 02
Racking inspected and certified, network and power tested under load.
03
10–14 weeks (parallel)

Integration & Build

WMS data view configuration, SQL allocation engine, middleware service, OPC tag setup, control portals. Runs in parallel with civil works to compress overall timeline.

[ Deliverables ]
  • WMS schema and data view configuration
  • SQL allocation engine implementation
  • Middleware service development & deployment
  • OPC tag layer / Kepware setup
  • Operator and supervisor portals
▸ Stage Gate 03
All interfaces passing the automated regression test suite.
04
4–6 weeks

Testing & Training

End-to-end test scenarios, failure-mode rehearsal, operator and supervisor training, runbook development, dry-run pilot. The phase where teams build muscle memory.

[ Deliverables ]
  • End-to-end test scenarios passing
  • Failure mode tests (comm loss, PLC fault, etc.)
  • Operator certification program
  • Supervisor playbooks and runbooks
  • Successful dry-run pilot
▸ Stage Gate 04
Operator certification and a fully successful dry-run pilot.
05
4–8 weeks

Go-Live & Hypercare

Phased ramp-up, on-site support team, daily issue triage, KPI tuning, formal handover to operations and steady-state support.

[ Deliverables ]
  • Phased lane-by-lane (or line-by-line) go-live
  • On-site engineering support team
  • Daily issue triage and KPI review
  • System tuning to target throughput
  • Formal handover and steady-state support agreement
▸ Stage Gate 05
System hits target throughput KPIs for two consecutive weeks.
[ How We Think ]

Three principles that
guide every engagement.

01

Phased over big-bang.

We never replace a working system in one shot. Every cutover is staged — lane by lane, line by line — so operations stays running and any issue is contained to a single zone.

02

Observable by default.

Every service we ship is monitored from day one. If something goes wrong, the team sees it immediately — not when a supervisor walks the floor and notices the line is down.

03

Manual fallback always.

Automation should never trap your operation. Every system we deliver has a documented manual fallback that lets your team revert to the prior process at any time, with no data loss.

Ready to walk through your specific situation?

Schedule a Workshop