Warehouse execution case study · Order fulfillment ERP
How a basic PDF pick ticket became a fully paperless warehouse execution system built on Dolibarr — eliminating nearly $2,000 a month in losses from cancelled orders that shipped anyway.
Prior operating experience led by Built-N-AI founder Casey Jackson. Company identity is omitted.
Results at a glance
The challenge
Implementing a new ERP created an opportunity to rethink one of the most fundamental warehouse processes: order picking. Dolibarr provided a basic PDF document usable as a pick ticket, but simply automating the printing of that document would have preserved every weakness of the paper-based process it came from.
Once a ticket reached the warehouse floor, visibility and control were limited. Tickets could be misplaced, employees had little insight into changes made after printing, and management could not easily tell exactly where an order stood in fulfillment.
The most expensive weakness: an order could be cancelled after its pick ticket had already printed, and the warehouse would have no way to know. Picking, processing and shipping continued anyway — about 20 times a month, costing nearly $2,000 in lost product.
“Instead of automating an outdated paper process, we redesigned fulfillment around what became possible once the warehouse, inventory and ERP were connected digitally.”
The solution
We designed a digital workflow integrated directly with Dolibarr that manages an order from the moment it becomes eligible for fulfillment through picking, quality control and shipment.
The system continuously evaluates sales orders against inventory availability and fulfillment rules. When an order qualifies — whether it needs a complete shipment or permits partial fulfillment — a digital pick ticket is created automatically and the order enters the Picking Queue.
Live, end to end
The system provides live status visibility across the entire fulfillment process: Order Created → Pick Queue → Wave Assigned → Picked → QC → Waiting to Ship → Shipped. At any moment, authorized users can see exactly where an order stands.
At QC and shipping, the employee scans the tote and the entire order appears. Where appropriate, they validate the transaction with a simple Pass/Fail action rather than manually processing individual items and system transactions — fewer clicks, same control.
What changed
The digital architecture solved the most expensive weakness in the old process: a printed pick ticket could stay active on the floor even after the order behind it was cancelled.
When an order is cancelled, its digital pick ticket and sales order cancel with it, the product returns to Finished Goods, and the tote is blocked from shipment.
This is agentic — the system doesn’t just flag the cancellation, it takes the next three actions on its own.
If an employee scans a blocked tote, the system immediately warns them the order was cancelled and tells them where the product needs to go.
The system recommends which unit to pick based on FIFO logic. If it isn’t physically in the expected bin, an authorized user can override and select another appropriate unit.
Guardrails, not a free-for-all: the system recommends, and only an authorized override can deviate from it.
An overridden or missing unit is automatically moved to a non-sellable holding status until it’s located and returned to a sellable bin.
Every action — picking, tote assignment, QC, shipping, cancellations, overrides and inventory moves — is logged with who, what and when. Full explainability: nothing the system does is a black box after the fact.
Before & after
Paper pick ticket, no visibility once on the floor
Fully digital, live status at every stage
Cancelled orders could still ship (~20/month)
100% blocked automatically, ~$2,000/month recovered
No wave sequencing, retraced steps on the floor
Wave-based picking, sequential bin order
Manual line-by-line QC and shipping processing
Scan the tote, Pass/Fail the order
FIFO enforced manually, if at all
System-recommended FIFO with controlled override
Missing inventory could stay listed as sellable
Automatically moved to non-sellable holding
Little traceability on exceptions
Complete audit trail of every action and exception
Business impact
Digital cancellation now blocks the tote before it can ship.
Recovered product returns to Finished Goods and resale availability immediately.
Every step is digital, from pick-ticket creation through shipment.
Management sees exactly where every order stands, in real time.
Every transaction and exception is traceable to a person and a timestamp.
Founding Client Program — 3 spots
This workflow was built and proven inside real operations, not sold before it was tested. The first three external clients get founding-client pricing in exchange for a case study and testimonial.
Step 1 — Pilot
A 2-week pilot digitizing one pick-to-ship flow, proving live order visibility on your own warehouse floor. Credited toward the full build if you move forward.
Step 2 — Full build (founding-client rate)
The full paperless wave-picking system integrated into your ERP, covering pick, QC and ship. Founding-client pricing for the first 3 external clients only.
Key takeaway
Rather than digitize the same paper workflow, the system was redesigned around what became possible once the warehouse, inventory and ERP were connected in real time.
The result: paperless picking, live visibility, and an automatic stop on the single most expensive leak in the old process.