Imagine running an online store where each product lives in a different warehouse. One item ships from Location1, another from Location2, and yet another from Location3. Now, imagine trying to manually figure out which warehouse should ship what, and when. Sounds like a nightmare, right?
That’s exactly the challenge one of our clients faced. They were juggling multiple warehouses, mixed orders, and zero automation.
The result? Slow order processing, frustrated warehouse teams, and customers waiting for tracking updates that never came.
The Problem: Too Many Cooks in the Warehouse
Their system simply couldn’t think for itself. Orders needed human intervention to figure out:
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Which warehouse should fulfill which product
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How to split mixed orders
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How to track shipments accurately
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How to coordinate “combined orders” across warehouses
The business needed a solution that could work smarter, not harder.
Our Approach: Let the Machines Do the Thinking
We built a custom order management system using Shopify and Mechanic. Think of it as giving the warehouses a super-smart assistant that never sleeps. Here’s what it does:
1. Smart Order Routing
No more guesswork. Our system:
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Reads product locations (thanks to Shopify product metafields)
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Automatically splits orders that span multiple warehouses
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Sends single-warehouse orders straight to the correct fulfillment center
2. Dynamic Fulfillment Logic
Each warehouse combination follows a specific fulfillment workflow to ensure smooth and accurate order handling.
Pure Orders
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Pure Location 1, Pure Location 2, and Pure Location 3 orders are shipped directly to the customer.
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Each location receives a label generation link, and Shopify is updated automatically with tracking information.
Location 1 + Location 2 Orders
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Location 1 receives the entire order, including items belonging to Location 2.
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Location 2 receives its own order lines (including any print or customization details).
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Location 2 sends its items internally to Location 1.
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Once all items are received, Location 1 ships the complete order to the customer.
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Both packing slips clearly display “SAMLEORDRE” for visibility.
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Only Location 1 generates the shipping label; tracking updates are synced with Shopify automatically.
Location 1 + Location 3 Orders
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Location 1 and Location 3 each receive only their respective items.
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Both locations ship separately to the customer.
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Each location gets its own label generation link, and tracking updates are pushed to Shopify.
Special Handling
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Orders containing custom or print-based items are automatically flagged for special handling.
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Ensures internal transfers (e.g., from one location to another) are completed before the final shipment.
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Automated workflows manage order splitting, email notifications, and label generation to minimize errors.
3. Automated Communication System
Warehouse teams now get exactly what they need:
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Customized PDF packing slips with only their relevant items
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Clear flags for “SAMLEORDRE” orders that need coordination
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Automated emails, no more chasing down information
4. Integrated Shipping Management
Shipping and tracking? Fully automated.
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Labels generated automatically via Shipmondo
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Tracking info pushed directly to Shopify
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Goodbye, manual entry; hello, efficiency
The Results: From Chaos to Smooth Sailing
Here’s what changed:
Operational Wins:
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Orders routed automatically, instantly
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Processing time drastically reduced
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Zero routing errors
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Clear visibility for combined orders
Business Wins:
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Scalable system, handles complexity with ease
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Cost savings from reduced manual labor
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Faster deliveries and accurate tracking = happy customers
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Smooth warehouse coordination, no more confusion
Why This Is Different
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Smart handling of mixed-warehouse orders
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Custom print services fully integrated
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Flexible shipping rules for every product combo
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Automated tracking updates, straight to Shopify
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Scalable architecture for future growth
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Scalable architecture for adding new warehouses anytime
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Customizable packing slips and emails to match any workflow or branding
The Takeaway
Running multiple warehouses doesn’t have to be messy. With the right automation, orders flow effortlessly, warehouses communicate clearly, and customers get their products faster.
And because the system is scalable to unlimited warehouses and offers highly customizable communication tools, it grows with your business instead of holding you back.
We turned chaos into clarity, and the client couldn’t be happier.
If your fulfillment process feels like chaos right now, let’s talk. We’ll help you automate, scale, and simplify your operations so you can focus on growing your business, not chasing orders.