We rebuilt our Lahore warehouse to hit a 4 PM same-day cutoff. Here's the before/after — pick paths, bin scanning, and what went wrong.
In late 2025 our dispatch cutoff was 11 AM — anything ordered after that shipped the next day. Farms hated it, and we lost orders to faster competitors.
The fix wasn't more staff. It was bin slotting, two-step picking and a barcode workflow that catches mis-picks at pack instead of at the customer. We went live in three phases.
Phase one was inventory accuracy. We cycle-counted the top 200 SKUs weekly until variance dropped under 1%. Phase two was reslotting — fast movers to the front, by velocity not by category. Phase three was the scanner workflow.
Today we cut at 4 PM and ship same-day, every day. The system isn't perfect (we still mis-pick about 1 in 800), but every error is now caught at pack — never at the farm.