OVERVIEW
A busy multichannel e-commerce warehouse was facing growing pains. With over 100 customer orders fulfilled daily, the operation was reliable but increasingly strained. Workers lost time walking back and forth to retrieve shipping labels from fixed printers, and outdated handheld devices frequently froze mid-process. The warehouse handled high-value electronics averaging $1,000 per unit, and barcode scanning was often skipped due to the reliability of devices, risking costly errors. EpicRise stepped in with targeted upgrades: mobile printers, rugged handheld computers, and standardized scan-based workflows. The results were immediate; orders shipped nearly 20% faster, packing errors dropped by 70%, and the company saved over $50,000 annually.
BACKGROUND
The warehouse was well-structured and fulfilled sameday orders with over 98% accuracy. It used a WMS compatible with major e-commerce platforms and barcode devices from Zebra and Honeywell. As volume grew and is projected to continue its growth, EpicRise’s audit revealed two recurring issues: excessive walking to retrieve labels and unreliable mobility devices. Staff often skipped barcode scanning during peak periods due to device crashes, risking mispacks and traceability failures. Given the high value of inventory, even a single
error could result in significant financial loss and customer dissatisfaction.
KEY CHALLENGES
- Lost time due to operators having to use time to walk to and from centralized printer stations.
- Unreliable mobility devices, risking missed scanning of high-valued products.
EPICRISE’S APPROACH
EpicRise evaluated current workflows and identified inefficiencies in labeling, device reliability, and verification processes. Workers were walking back and forth to fixed stations just to print labels, increasing delays and the risk of misapplied labels. Generic mobile devices frequently lost connectivity or failed under heavy use, which disrupted operations and slowed order fulfillment. In addition, the lack of standardized verification steps left room for errors to pass unnoticed.
To address these issues, EpicRise proposed a mobile-first strategy that integrated printing, rugged devices, and scan-based checks directly into daily workflows. This allowed workers to handle labeling, scanning, and verification directly at the point of use, eliminating interruptions and extra steps.
SOLUTIONS DELIVERED
- Mobile Computers: Honeywell CT47 and CK62
- Printers: Zebra Zt610
- Scanners: Datalogic PowerScan PD9531
- WMS Implementation:
- Real-time inventory visibility
- Structured put-away and internal circulation tracking
- FIFO/FEFO enforcement
- Full traceability with digital logs
- Created standardized SOPs and provided onsite worker training
SOLUTIONS DELIVERED
EpicRise introduced mobile label printing using the Zebra Zt610, which integrated directly with the WMS. This allowed workers to print labels instantly at the point of use, eliminating unnecessary walking and ensuring accurate label application. They also replaced generic handheld devices with rugged Honeywell CT47 and CK62 mobile computers, offering reliable connectivity, fast scanning, and durability in demanding environments. Finally, EpicRise standardized scan-based verification as a required step in order fulfillment and trained staff to adopt mobile-first workflows.
RESULTS
Within three months of implementation, the warehouse saw significant operational improvements:
- SKU verification compliance reached 100% utilizing reliable mobile device, ensuring each product was scanned
- Order fulfillment speed increased by 18%, supported by Honeywell devices that delivered both speed and accuracy.
- Packing errors dropped by 70%, reducing costly mistakes.
- Estimated savings of $50,000+ annually from fewer mispacks and error-related losses.
- Worker efficiency improved 15%, as employees no longer worried about scanning slowing down their workflow.
- Device reliability improved 100%, with zero downtime reported after the Honeywell upgrade.
"Our team used to lose valuable time walking back and forth for labels, and the old handhelds froze so often that we sometimes had to cut corners just to keep up. Since moving to mobile printers and rugged Honeywell devices, everything flows smoothly. We can scan every item without worrying about crashes, labels are applied right at the station, and errors have nearly disappeared. It’s taken a lot of stress off the floor and given us confidence that every order leaving our warehouse is right the first time." — Warehouse Manager
CONCLUSION
EpicRise’s targeted audit and solution roadmap helped this high-volume e-commerce warehouse enhance accuracy, speed, and reliability. By implementing mobile printing and upgrading mobile computers, the company reduced costly errors, protected high-value inventory, and eliminated device-related downtime. This project demonstrates EpicRise’s ability to fine-tune established operations, delivering measurable cost savings and performance improvements while strengthening customer trust.
