Modernizing LexonUK’s warehouse operations required bridging outdated hardware with modern software—legacy barcode scanners and conveyor belts lacked API support, forcing manual data entry and causing a 15% error rate in shipments. Seasonal demand spikes overwhelmed the system, leading to delayed orders and frustrated customers. The existing PHP platform couldn’t scale horizontally, and the lack of real-time tracking meant staff often mismanaged inventory, resulting in stockouts or overstocking.
Prioritizing rush orders was another pain point. Without automated workflows, high-priority requests were buried in queues, and customers lacked visibility into shipment statuses, leading to constant support queries. The warehouse team struggled with clunky interfaces that slowed order processing, and the absence of error-checking mechanisms allowed incorrect shipments to slip through.
02 . The Solution
Middleware APIs connected legacy devices to the PHP backend, automating inventory updates. An AI validation layer cross-checked orders against stock levels, reducing errors by 40%. A priority scoring system flagged urgent orders, and real-time tracking APIs (e.g., DHL) provided customers with shipment updates via SMS/email. The database was restructured for scalability, and staff dashboards displayed color-coded order statuses, cutting processing time by 50%.
Optimized by Seraphinite Accelerator