How We Replaced Scissors with Algorithms for a Multi-Country Bedroom Products Seller

This bedroom products e-commerce company sells beds, mattresses, cushions, duvets, and accessories across 5 Shopify sites and approximately 20 marketplaces in France and Spain. Its catalog has two distinct logistics categories: bulky bed components (headboards, frames, bases, mattresses) shipped as kitted multi-package orders, and accessories (cushions, mattress toppers, duvets) with packaging rules that vary by combination and quantity. It operates a main facility in France and a Spanish site divided into zones for cushions, bases, mattresses, and bed packaging materials.

The Challenge

The company came to us with a single core complaint: order preparation was entirely manual. When an order arrived containing, say, a bed frame and three cushions, someone had to print the order, physically cut it apart, and manually route each piece to the right warehouse and sub-warehouse. The bed components went to France; the cushions might need splitting across two zones of the Spanish warehouse; accessories required hand-calculated packaging decisions on every order — 4 cushions fit in one box, but 5 need two; 2 cushions plus a mattress topper is one box, but 3 cushions plus a topper is two. Beyond order splitting, traditional warehouse automation was off the table: their products come primarily from China and Turkey, where barcode reliability is inconsistent. The same product might carry different barcodes depending on the manufacturing run or country of origin. PDA-based scanning workflows simply weren't feasible. And when packages were finally ready, there was no way to immediately confirm shipping to their 25+ sales channels — they were dependent on carrier pickup as the trigger, which could happen the same day or two days later, creating marketplace SLA compliance problems.

The Solution

We redesigned their entire fulfillment chain in three connected layers: algorithmic order orchestration, integrated label printing, and scan-based tracking updates.

When products come from China and Turkey with inconsistent barcodes, traditional PDA scanning simply isn't an option. The integrated label turns a plain A4 sheet into a complete fulfillment document: pick list, packaging instructions, carrier label, and tracking barcode — all in one.

The Results

The entire fulfillment chain is now automated end to end. Order splitting that previously required printing, cutting with scissors, and manual routing now happens in milliseconds on order arrival. Packaging decisions that required mental math on every single accessories order are now enforced by rules. And tracking updates that used to lag carrier pickup schedules now fire immediately when packages are sealed, keeping all 25+ marketplaces compliant with their SLA requirements.