CASE STUDY: Automatic Shipping and QC System

pack verification

The Problem – Need a 100% accurate shipping system

CASI was approached by a manufacturer of food safety test kits with the challenge of developing a shipping system that would guarantee 100% order accuracy. Shipping labels and special paperwork would have to be printed from the system. In addition, the system would need to record a proof of fulfillment video of the entire operation.

The Solution – SolidPack Proof of Order and Fullfillment

CASI install SolidPack, a module from the SolidSuite Warehouse Control System (WCS) along with an interface to the customer’s legacy SPT ERP System.


  1. SolidPack
  2. SolidComm
  3. SolidShip
  4. 1100 System computer with I/O
  5. Cordless handheld Scanner
  6. shipping scale
  7. Report printer
  8. Thermal Transfer Shipping Label Printer

Pick and Pack System Overview

The system starts with a custom interface into the SPT ERP system to get the order information using SolidComm. A paper pick ticket is used by the customer’s picking system as shown below:

pick ticket verify

This barcode represents the order that is being processed. The entire order is downloaded in less than 50 ms by the SolidComm system. Once the order is local, the system tells the operator to place the shipping carton on the scale. This provides the system with the tare weight for the shipping carton.

pack weigh scale

Solidpack is voice enabled and speaks up to five languages. It tells the packer to scan the first item and place it in the box. The system has an expected weight for the item and check weighs each item as it is placed in the shipping box.

verification of order ticket

As each item is placed in the shipping carton, it is verified by barcode and weigh. In addition, the system builds a proof of fulfillment video using the attached fire wire camera.

pack verify

This process continues until the carton is full.

full package verification

Special paperwork such as packing lists, instructions and collaterial material can be added at this time.

video proof packing

Once the packing list and collateral paperwork is included, the case is sealed on the scale and a shipping label printed using SolidShip. SolidShip interfaces to all carriers from each individual pack station.

packing verification

The video reports can be viewed at any time by customer service and emailed to customers with questions about their order and missing or incorrect items. Since installing the system, the customer has had ZERO mispicked or shipped items.

Benefits from the new efficiencies

Benefits from the new pick and pack system include elimination of mispicked orders, reduced labor costs due to labor statistics, faster and more predictable order processing.

For order and more information:

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