Executive Summary
Caronlab Australia successfully scaled its operations to handle a 100% increase in daily order volume without increasing warehouse dispatch headcount. By integrating eveXso WMS with MYOB EXO and OpenFreight, Caronlab transitioned from manual, delayed system updates to point-of-activity data capture. This shift has eliminated operational friction, improved inventory visibility, and positioned the business for scalable growth without increasing administrative complexity.
The Challenge: Operational Bottlenecks Threatening Growth
Caronlab operates a growing distribution and manufacturing environment where warehouse responsiveness and inventory visibility are critical to maintaining service levels and supporting continued business expansion.
Prior to implementing eveXso, warehouse processes relied heavily on manual transaction handling and delayed system updates. As order volumes increased, this created operational pressure across areas such as inventory visibility, dispatch coordination and administrative effort required to maintain system accuracy.
The "Before" State
- Manual Transaction Handling: Warehouse processes relied heavily on manual data entry, creating a "data lag" between the physical warehouse and MYOB EXO. This led to dispatch staff struggling to keep up, often trailing three days behind.
- Single-Person Dependency: Because stock locations weren't captured digitally at the point of activity, the team relied on a single store person's memory. If that person was away, the team lost hours searching for products.
- Fragmented Visibility: With only yearly stocktakes, "Stock on Hand" figures were consistently inaccurate, leading to incorrect picks and costly shipping errors.
- Proportional Complexity: As volumes increased, the administrative effort required to maintain system accuracy threatened to erode profit margins.
"We were relying purely on Exonet, with yearly stocktakes. Somehow our stock on hand was always out... only our store person knew where the items were, if he was out, we would spend hours looking for the items."
Julian Ure
Business Operations Manager, Caronlab Australia
The Solution: Real-Time Operational Control with eveXso
Caronlab required a warehouse execution platform purpose-built for high-volume environments that could handle complex logic—such as Works Orders for manufacturing—without the cost of a full ERP replacement.
Why eveXso?
Integrated directly with MYOB EXO, eveXso enabled warehouse movements to be captured at the point of activity, improving accuracy and reducing reliance on manual reconciliation.
Logistics Synergy
The direct integration between eveXso and OpenFreight provided a seamless end-to-end flow for dispatch and freight, removing the "friction" of fragmented shipping processes.
Strategic Integration
Partnering with Kilimanjaro Consulting, the eveXso team focused on data hygiene and cleaning up 50,000 account address formats to ensure the new digital workflow was built on a clean foundation.
Point-of-Activity Innovation
Caronlab developed custom scanning logic for outer cartons. This allows the WMS to process bulk boxes instantly, increasing execution speed in both receiving and dispatch.
The Outcome: Scalable Execution and Improved ROI
Since implementing eveXso, Caronlab achieved improved real-time visibility of inventory and warehouse activity, enabling more confident dispatch planning and reducing operational friction associated with delayed updates and fragmented processes.
1. Doubling Throughput with Reduced Headcount
The most significant impact was seen in dispatch efficiency. Previously, a team of five full-time staff handled roughly 40 orders and were often days behind. Today, a smaller team of four (including two part-timers) comfortably manages 80–90+ orders per day.
Before eveXso
- 30-40 orders per day
- 5 full-time dispatch staff
- 3+ days behind in peak
- Yearly stocktakes / Often "out"
- Single-person dependency
With eveXso
- 80-90+ orders per day
- 4 staff (incl. 2 part-timers)
- Current (Max 2 days in peak)
- Daily rolling checks / "Best shape ever"
- System-driven & Scalable
2. Confidence Through Inventory Visibility
By capturing data at the point of activity, Caronlab moved from "once-a-year" counts to daily rolling stocktakes. Julian notes that the stock system has "never been in such good shape," allowing for more confident dispatch planning.
3. Proactive Operational Control
Real-time visibility allows the team to pinpoint discrepancies immediately. Caronlab can now quickly identify an incorrect shipment and resolve the issue before the package even arrives, significantly improving customer service retention.
4. Rapid Adoption
The warehouse team adopted the new technology with ease. "Everyone just seemed to get it without much hassle", leading to a more confident and autonomous workforce.
How did eveXso help Caronlab scale without adding staff?
By replacing manual processes and single-person knowledge dependencies with system-driven workflows, eveXso enabled Caronlab to process double the order volume with a smaller team. Real-time inventory visibility, automated dispatch workflows, and daily rolling stocktakes eliminated the bottlenecks that previously required additional headcount. The integration with OpenFreight further streamlined freight management, removing another layer of manual work.
The Long-Term Value of Warehouse Execution
For operations leaders, the transition to eveXso represents a move toward a "future-proof" warehouse where growth no longer leads to proportional increases in administration or complexity.
"Getting a system like eveXso works out better than you could imagine and it only gets better long term... Our stock system has never been in such good shape and it definitely would not be without eveXso."
Julian Ure
Business Operations Manager, Caronlab Australia
