The main issue facing the e-commerce provider was delays in label printing and the number of units workers could process per hour. Manual label printing slowed the workflow and led to an increasing number of errors as demand increased. Each worker could handle only a limited volume, and the time required to print labels added to the backlog. As the number of units increased, the margin for error widened, reducing throughput and causing daily operations to become inconsistent. These problems made it clear that a more efficient and accurate process was required.
After learning about the provider’s operational challenges, NPSG began designing the automated scanning and label application system. The design process lasted six months and required careful engineering. One of the most significant challenges was finding a way for the semi-automated system’s frames to rotate for scanner maintenance without being anchored to the floor. Traditional systems often rely on fixed structures, but this project required mobility and flexibility. The engineering team developed a solution that allowed the frames to rotate securely and safely while providing easy access for technicians. This design not only addressed the provider’s needs but also established a new benchmark for adaptable, easy-to-maintain systems.
With the design finalised, NPSG moved into the procurement phase. This stage proved demanding because the e-commerce provider asked NPSG to identify suppliers and vendors who could meet strict requirements and contribute to a successful implementation. NPSG conducted extensive research to identify partners who offered the right materials, expertise, and reliability. The team assessed each supplier to ensure compatibility with the project timeline and quality expectations. Through persistence and careful vendor selection, NPSG overcame this challenge and secured the necessary resources.
After procurement, NPSG prepared to deploy installation teams across Germany. As the project involved sixteen separate sites, scheduling became a crucial part of the strategy. NPSG was working under a tight deadline, requiring a coordinated approach to keep the project on track. To meet the timeline, NPSG assigned multiple installation teams to work simultaneously at different locations. This strategy enabled parallel progress and prevented unnecessary delays. By deploying teams concurrently, NPSG remained aligned with the project schedule and maintained consistent progress across all sites.
Once installation was complete, NPSG entered the commissioning phase, one of the most critical stages of any large-scale deployment. The purpose of commissioning is to ensure that the automated scanning and label application system performs correctly before it becomes part of daily operations. During this phase, NPSG tested software configurations, system integrations, functionality, calibration, and overall reliability. Commissioning allowed the team to identify and resolve any issues early. This stage ensured that the system met quality standards and operated safely and efficiently. The thorough testing conducted by NPSG validated the durability and performance of the new solution.
Throughout the project, NPSG faced multiple challenges that required quick thinking, cooperation, and creative problem-solving. One major challenge was identifying vendors who met the project’s requirements. Because the scope was extensive and the timeline was strict, NPSG needed suppliers who were dependable and capable of delivering the necessary components. Through detailed research and careful evaluation, the team selected the best partners, protecting the project’s integrity and meeting the customer’s expectations.
Another challenge involved engineering coordination across time zones. Although NPSG operates internationally, the engineers assigned to this project were all based in the United States. With the project taking place in Europe, the time difference created scheduling difficulties. To overcome this, NPSG arranged for some engineers to travel to Europe so that aspects of the project could be managed in person. Engineers who remained in the United States adjusted their schedules and often attended meetings outside their regular working hours, including very early morning sessions. This approach ensured constant communication, uninterrupted progress, and strong support throughout the project. The engineering team’s willingness to adapt demonstrated NPSG’s commitment to delivering high-quality solutions despite logistical challenges.
Upon completion of the project, the e-commerce provider expressed strong satisfaction with NPSG’s work. The company appreciated the resourcefulness and determination shown throughout the entire process, as well as the consistent effort to overcome challenges. The project, which generated €2 million in revenue, represented a significant achievement and demonstrated NPSG’s ability to execute a complex concept from initial design through to final implementation. NPSG completed the work across sixteen warehouses and delivered a solution that resolved the provider’s key challenges. The automated scanning and label application system improved accuracy, reduced labour strain, increased throughput, and introduced a more dependable workflow.
The success of this project reflects NPSG’s dedication to understanding customer needs and developing solutions tailored to the scale and complexity of each environment. Through resilience, collaboration, and persistent problem-solving, NPSG demonstrated the value it brings as a trusted partner in automation integration and innovative warehouse solutions.