E-commerce & Logistics · United States

The operation was labour-heavy: 2,000–3,000 parcels a day absorbed six packers plus a large sorting crew, and the shift still ran past five hours. Local labour efficiency fluctuated and manual sorting was slow, so adding people no longer added output.

We re-engineered the packing and sorting flow with a customised line layout, merging packing and sorting into one continuous process with scanning and weighing at the merge point, and preset chutes replacing manual pre-classification.

The line handles mixed parcel formats at the merge, scan and weigh stations, then routes each parcel to its preset chute automatically — no manual pre-sorting, and exceptions are diverted before they block the line. It processes up to 3,000 items per hour, absorbing front-end packing output with no backlog.