Streamlining Warehouse Operations: A Logistics System Upgrade

Revamping Logistics Operations through Technology Upgrade

Project Overview

The client approached Ebryx Tech to improve logistics service. The requirement was to automate manual workflows and resolve bugs in the existing system. Through Ebryx Tech’s expertise, the client’s warehouse operations were fully automated and made error-free. It also enhanced user experience and productivity. 

Client Information

The client is a 3PL service provider based out of East Coast United States. With a focus on improving warehouse productivity and performance, the company offers professional services, including auditing and selecting services, at over 30 locations in 22 states.

Key Challenges

Prior to its effective use, the client's existing system had several bugs and performance issues. Additionally, the system had not been designed to be easily scaled, making it difficult to accommodate larger user bases. The system had to be enhanced with new features and improvements in order to fully automate manual workflows and tasks. This was needed to reduce the amount of time spent on tedious tasks and enable employees to focus on higher-value assignments. Additionally, it was anticipated that automating certain processes would lead to cost-cutting and fewer instances of human error.

Following is the detail of associated challenges in this respect:

Manual Reporting System

Handhelds are modern, Windows-based tablets that are designed to withstand the harsh environment of warehouses. The software had the capability to track various time brackets such as when the shipment arrives, when someone is assigned to unload, when unloading begins, and when it ends.  


Error Detection

The handhelds’ existing software required manual error detection and subsequent data updating. Additionally, the reporting system was primarily manual, which could result in delays and errors in the process. These handhelds were also commonly used by employees and lumpers to mark their attendance.

Unoptimized Load Importer

Client was facing difficulties in syncing its in-house scheduling mechanism with that of its customers’, usually exportable in the form of excel or csv. In order to sync with that schedule, the client deployed its Load Importer on the site. However, it required feature improvements to avoid the frequently occurred scheduling problem.

Inefficient Dock Management

In a logistics warehouse, dock management can be a challenging task. Without proper monitoring and scheduling, there can be delays in logistic operations. The client was experiencing difficulties in managing the loading and unloading of trucks efficiently in their logistics warehouse. They were also struggling to allocate resources effectively and provide accurate information on the status of shipments to their customers.

Disruptive System Outages

The client faced issues with system downtime due to unpredictable weather conditions, power outages, and other factors, resulting in discontinuity of logistics operations. The absence of system availability caused significant disruptions and delays, leading to frustration among the client’s workforce. 

Outdated Payment Infrastructure

Amid the COVID-19 pandemic, drivers and logistics staff were hesitant to engage in close proximity interactions for fear of transmission. 

Project Scope

The project goal was to create a functional website, Windows and mobile applications, along with their supporting applications across multiple platforms. The team first created the supporting applications, and developed the remaining applications in tandem. The process also involved creating a portal and incorporating additional data sources. Various technologies such as SQL, Windows Server, Windows 10 and 11, iOS and Android applications were utilized.

Solution Delivered

Ebryx Tech first thoroughly reviewed and understood the existing system and business rules. After completing the analysis, the team began developing the system using an iterative and incremental process. The team presented a comprehensive migration plan after completing the core features and implemented it. The legacy system was ready for the move.

The solution included the following components in detail:

Automated troubleshooting and synchronization on Handhelds

The software was updated and now the system has been made capable of detecting errors automatically without the need for human assistance. The best part about the application on these handhelds is that it can run offline – even for days without worrying about internet connectivity, power shutdowns, etc. Once the connection is available again, the app starts and then keeps syncing with the central servers on cloud to preserve data. The collected data not only helps to monitor progress but also enables the backend system to generate several reports. The synchronization involves a very complex yet efficient algorithm, which is responsible for uploading real-time data for real-time tracking. 

Real-time Dock Management

We provided a dock monitor system that offered real-time information on the status of each dock and yard. This system allowed the client to optimize dock scheduling and reduce waiting times for incoming trucks, which improved operational efficiency and customer satisfaction. The system also provided real-time information on the location and status of all trucks in the yard, making it easier to manage loading and unloading processes.

Load Importer Optimization

We incorporated feature updates in the Load Importer, and this tool now integrated the client’s schedule seamlessly into their customer’s transportation management system, providing real-time information on shipments. It included server configurations to ensure accurate and up-to-date data and helped dock staff sync with the client’s schedule for optimized loading and unloading processes.

Ensuring Continuous Operations

Ebryx Tech has successfully addressed the issue of system downtime and discontinuity of operations by creating an online web portal and mobile app. 

It is a cloud-based application which can be accessed from anywhere in the world. Everything that is entered through Handhelds can be seen here after synchronization. The web portal has numerous features. The salient ones are: 

  1. Role-based user authorization
  2. Configuration interfaces for sites or warehouses
  3. Load editors to review/enter unloading data and specifics 
  4. User management
  5. Interfaces for Employees (Lumpers) employments, certifications, time-tracking, and write-ups
  6. Custom reporting which allows end users to add reports on the go with customized datasets

Both iOS and Android versions of the mobile app are available on relevant online stores. This app is a lighter version of a web portal, which comes in very handy when going through real-time updates. The prominent features include but are not limited to: 

  1. Dashboard for a quick summary of the day on a site
  2. Different reporting interfaces for a brief and comprehensive view of shipments
  3. Notifications about important happenings on a regular day 
  4. Role-based authorization and interfaces
  5. Reports for employees on unloading and time spent 

Relay Payments

A rapidly growing Atlanta-based company was onboarded to provide digital payments for the logistics business. The system was fully integrated into the company’s operations to match the modern trend of contactless payments. By using this system, drivers were able to get off the dock faster and ensure timely reimbursements. Additionally, the contactless payment system provided a safe and trustworthy channel for payments during the Covid-19 pandemic.

“If we had any worries about any aspect of the development, they were able to work through everything and were always able to provide options that met our needs.”

Technology Stack.

The Results

Ebryx Tech completed the project and integrated the new system seamlessly into production. The additional functionalities resulted in substantial time and cost cuts for the client.   The client benefited from faster load collection processing, improved information accuracy, and effective auditing measures to address inconsistencies and improper usage. Upon evaluating the system’s outcomes and effectiveness, the client decided to continue collaborating with Ebryx Tech for further system expansion.

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