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Case study · Supply Chain & Distribution

Unifying Disconnected Regional Fulfillment Centers into an Event-Driven Operations Engine

Engineered an event-driven operational core that integrated disparate legacy warehouse management and ERP systems, eliminating 18 hours of manual reconciliation per shift and achieving deterministic order dispatch.
ContextFortune 500 Technology & Supply Chain Distributor6 Months Engagement

The challenge

What was making the work difficult.

Operating across multi-country distribution hubs, regional teams relied on asynchronous batch exports from legacy ERPs combined with local spreadsheets. Order exceptions required manual investigation across five separate systems, creating multi-day fulfillment delays during peak demand.

The approach

01

Distributed Event Bus & CDC Layer

Implemented Change Data Capture (CDC) over legacy transactional databases, streaming inventory state mutations into a centralized Apache Kafka message bus with sub-100ms propagation.

02

Deterministic Exception Orchestration

Replaced unstructured email and spreadsheet escalations with a state-machine-driven dispatch engine that assigns, audits, and auto-resolves inventory discrepancies.

03

Role-Governed Operations Cockpit

Built a unified, low-latency web cockpit providing floor managers and executive leadership with real-time throughput metrics, bottlenecks, and automated SLA alerts.

Reported outcomes

Results are described from the engagement context. Client details are anonymized where confidentiality requires it.

74%

Exception Resolution Latency

Reduced average investigation time from 18 hours to under 4.5 hours.

99.98%

Sync Consistency

Zero data divergence between warehouse floor actions and corporate inventory records.

4.2x

Peak Load Capacity

Handled record seasonal volume spikes with zero system throttling or dropped orders.

Tools used in this engagement

Next.js · TypeScript · Node.js · Kafka · PostgreSQL · Redis · Docker

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