Core Wins
Reclaimed ~70+ hours weekly across warehouse packing benches and sales order processing.
Near-elimination of physical picking errors and out-of-stock oversells across all channels.
Configured four dedicated warehouse zones: Pick, Storage, Goods In, and Returns.
Overview
Linnworks is the central engine of our business, managing inventory, orders, and courier dispatch across our websites and global marketplaces.
Originally, our warehouse ran on legacy Linnworks Desktop software combined with printed paper picking lists. Staff manually sorted orders into physical folders and walked invoices across the floor, leading to packing mistakes and stock overselling.
I managed the complete migration over to Linnworks.net and transformed our fulfillment floor into a fully digital, barcode-driven warehouse operation.
Process Comparison
Paper Picking & Desktop Software
- • Manual Batching: Office staff split incoming orders into physical paper folders by hand.
- • Paper Distribution: Printed pick sheets were walked to the floor and handed to warehouse staff.
- • Blind Picking: Staff picked items into trolleys guided entirely by paper sheets, causing mismatches.
- • Double Checks: A manager had to physically inspect every packed order to catch errors.
- • Manual Dispatch: Paperwork was walked back to desks for manual dispatch confirmation.
Barcode Handsets & Linnworks.net
- • Automated Order Routing: Orders flow into custom Linnworks.net views instantly via rules engine.
- • Handset Picking: Pickers scan barcode shelf locations directly into barcoded totes.
- • Scan-to-Print Packing: Scanning tote barcodes auto-validates items and triggers courier labels.
- • Auto Customer Tracking: Dispatch updates channels and sends tracking info automatically.
- • Direct Staging: Parcels are staged straight into carrier cages ready for collection.
Hardware Sourcing & Workflow Migration
Migrating to a digital warehouse required getting the physical infrastructure right.
I researched, sourced, and configured all hardware—handheld Android barcode scanners, custom-built packing benches, thermal label printers, and warehouse WiFi access points.
To support the new process, I migrated our order-start process over to Linnworks.net and built custom order views that guide pickers efficiently through daily order queues.
Hardware & Workstation Sourcing
Sourced and deployed Android barcode handsets, optimized packing workstations, and reliable label printers configured for daily high-volume dispatch.
Custom Order-Start Views
Configured tailored order views in Linnworks.net to separate single-item and multi-item orders, giving staff clear, prioritized picking batches.
Multi-Binrack WMS Architecture
Our product catalog contains thousands of militaria, clothing, and surplus lines that vary wildly in physical footprint, from small badges to heavy steel helmets.
I transferred and configured our WMS with advanced multi-binrack storage, replacing manual spreadsheets with systematic location tracking across four zones:
Pick Locations & Bulk Storage
Structured primary pick locations for fast picker access, backed by bulk storage binracks with automated replenishment logic.
Goods In & Returns Processing
Established dedicated staging areas for incoming stock checks and isolated returns processing, preventing uninspected kit from going live.
Technical Administration & System Logic
Beyond warehouse floor workflows, I manage the underlying technical logic and integrations across the Linnworks ecosystem.
Custom SQL Query Reporting
Wrote custom SQL queries in Linnworks to extract advanced reports on sales velocity, stock valuation, and restock timing that standard reports lacked.
Rules Engine Management
Built complex routing rules to auto-assign couriers based on weight, dimensions, value, and destination, routing 99% of orders with zero human intervention.
Multi-Channel Inventory Linking
Managed product linking and channel inventory sync across Magento 2, Shopify, eBay, and Amazon, keeping live stock strictly synchronized.
Shipping Carrier Integrations
Maintained direct courier API connections, label formats, and automated customs data flows for UK, EU (IOSS), and international services.