52% Reduction in Order Processing Time

A 40-person distribution company was spending over 30 hours per week on manual order routing, data entry, and inventory reconciliation. Errors were common, leading to shipping delays and customer complaints. The operations team had built workarounds on top of workarounds — but the fundamental problem was that every order required human touch at 5+ handoff points.

Meanwhile, marketing was running campaigns that drove demand the operations team couldn’t fulfill efficiently. The disconnect between marketing’s pipeline and operations’ capacity was costing the company an estimated $50K/quarter in missed opportunities and customer churn.

We started with a Foundation Sprint to map the entire order-to-delivery process and identify the highest-impact automation points. Within the first two weeks, we had a clear picture of where time was being lost.

Over the following four months, we implemented:

• AI-driven order routing that automatically classifies, prioritizes, and routes orders based on product type, inventory levels, and delivery requirements
• Real-time inventory synchronization between the warehouse management system and the e-commerce platform
• Automated exception handling that flags anomalies for human review instead of requiring human review for every order
• Unified marketing-ops dashboard connecting campaign performance to fulfillment capacity in real-time

The result was a system where 80% of orders flow from placement to fulfillment without human intervention, and the remaining 20% are flagged with context so the team can resolve them in minutes instead of hours.