The client’s fulfilment operations involve thousands of bags moving across handoff points daily. The problem was not that bags were disappearing — it was that nobody could prove it, quantify it, or assign accountability for it. Manual logging created gaps at every handoff. Reconciliation happened after the fact, by which point the chain of custody was broken.
The Flipr team spent the first two weeks on the fulfilment floor — observing every handoff, mapping process gaps. The root cause was not a technology gap. It was a process gap that technology could close.
We designed a real-time tracking system on barcode scanning at every handoff, feeding a central event log with automated anomaly detection. The AI layer flagged deviation patterns and escalated unresolved anomalies to supervisors within 90 seconds.
Every scan generates an event flowing through a real-time processing layer before being committed to the audit log. Anomaly detection operates on live data, not end-of-shift batch logs.
The dashboard became a standard part of floor management. Shift handover briefings now include a live bag count. Anomaly alerts are reviewed in the daily ops standup.
Within 90 days of go-live, bag loss dropped by 95%. The recovery rate on flagged incidents was 92%. The client rolled the system to additional facilities ahead of schedule.
The less visible outcome was accountability. The system created an unambiguous chain of custody at every handoff. The act of being measured was itself a reduction in loss.