CASE STUDY
CarParts.com orchestrates end-to-end fulfillment with inVia Logic WES
At a Glance
- 400% more workflow improvements with inVia Logic WES than WMS
in just 4 months - AI-optimized task flow across picking, replenishment, and packing
- Intelligent slotting for faster picks and safer handling of heavy items
- New hires reached 75% productivity within 1 hour using inVia PickMate
- Real-time dashboards to right-size labor and monitor performance
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CarParts.com, a leading eCommerce destination for automotive parts and accessories, operates in a fast-paced, high-volume e-commerce environment where fulfillment speed, accuracy, and safety are critical. As their operations scaled, they needed a smarter way to orchestrate tasks across all warehouse workflows—from inbound flow and storage to replenishment to picking and order consolidation—without adding complexity or delays.
Their goal was to implement a flexible, software-driven system that could optimize every workflow, support ergonomic practices to protect their team, and provide the real-time visibility needed to make data-driven decisions across the operation.
To meet these needs, CarParts.com deployed inVia Logic, inVia Robotics’ AI-powered WES software, along with the inVia PickMate productivity tool, equipping their team with a smarter system to increase agility, enhance safety, and respond faster across every fulfillment workflow.
“We chose inVia because their platform gives us the flexibility to manage all of our workflows—from inbound to order consolidation—without adding complexity. It’s a unified system that adapts quickly and keeps our teams moving.
Over a four-month period, we implemented 400% more WES improvements than WMS improvements, which proves inVia’s ability to adapt to our fast-evolving needs and support our commitment to delivering exceptional customer outcomes.”
Michael Huffaker, COO, CarParts.com
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The Solution
AI software orchestrates every fulfillment workflow
AI software orchestrates every fulfillment workflow
CarParts.com implemented inVia Logic, an intelligent automation platform that makes over 1 million decisions per day to coordinate workflows and resources across the facility. It determines what needs to be done, when, and where—ensuring every task is executed with precision.
Beyond orchestration, inVia Logic uncovers hidden inefficiencies that traditional metrics often miss—then uses those insights to improve workflows, optimize inventory placement, and refine pick paths. It guides the next steps for continuous improvement and resolves issues before they impact performance.
The platform dynamically assigns tasks to balance pick density and maintain smooth flow across picking, packing, and replenishment zones. It also prioritizes orders in real time, helping CarParts.com meet SLAs consistently, even during peak volumes.
Inventory slotting optimized for speed and safety
Inventory slotting optimized for speed and safety
inVia Logic WES uses data-driven logic to optimize inbound flow and storage by placing fast-moving SKUs in high-efficiency locations while keeping slower-moving items out of prime space to maximize throughput.
inVia Logic also reinforces CarParts.com’s Safety First core value by placing heavy or oversized products in ergonomic locations, promoting safe lifting practices, reducing physical strain, and supporting a safer, more efficient work environment.
inVia PickMate simplifies onboarding and task execution
inVia PickMate simplifies onboarding and task execution
The inVia PickMate productivity tool provides clear “Pick-to-Color” instructions along with product images and color-coded labels to ensure accurate picking and placement. System-directed tasks enable workers to move seamlessly between functions like picking and replenishment without delays. inVia PickMate also displays live productivity metrics, allowing associates to adjust their pace in real time to meet performance goals.
“inVia PickMate has revolutionized how our associates handle e-commerce fulfillment tasks. It reduced training time, boosted confidence, and drove smoother, more accurate operations, with new hires reaching 75% of our productivity standard within their first hour of training.”
Discrete to Batch Picking: Workflow Optimization in Just Two Weeks
CarParts.com wanted to move from a discrete picking model, where one order was picked at a time and sent directly to a conveyor for packing, to a more efficient batch picking model. But before making the switch, they needed to ensure that existing infrastructure, like their conveyor belt and packout stations, could support the change.
With inVia’s intelligent automation software, the transition took less than two weeks. Twin IQ simulated the new workflow ensuring material flow matched the conveyor and packout capacity. Once optimized, inVia Logic automatically deployed the updated process.
For warehouse associates, the shift was seamless. Pickers simply followed the updated instructions on inVia PickMate. No retraining was needed, and operations never missed a beat.
Actionable real-time visibility supports labor and quality decisions
At CarParts.com, inVia’s real-time dashboards give the team full visibility into associate performance, task status, and warehouse workload. Managers can monitor productivity, identify idle time, and even view inVia PickMate screens remotely to ensure processes are followed accurately. These insights allow CarParts.com to staff more efficiently, respond to exceptions quickly, and uphold high operational standards.
“The dashboards let us plan labor around real-time demand and catch issues early, whether it’s a missed step or a quality control flag. It’s a huge part of how we keep everything running smoothly.”
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The Result
After deploying inVia Logic WES and inVia PickMate, CarParts.com achieved:
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400% more workflow improvements than WMS in just 4 months, reflecting rapid adaptability to operational needs
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AI-orchestrated workflows across picking, replenishment, and packing that balance pick density and help meet SLA deadlines
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Data-driven slotting that boosts throughput and supports ergonomic handling of heavy products
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New hires reaching 75% productivity in under 1 hour, accelerating onboarding and increasing workforce confidence
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Real-time visibility into labor and task performance, enabling smarter staffing decisions and proactive exception management
With inVia’s intelligent software platform, CarParts.com now manages all core warehouse functions through a unified system—improving efficiency, safety, and responsiveness without adding operational complexity.
Implementation strategy that accelerated results
Phased rollout with minimal disruption: CarParts.com deployed inVia department by department as training and setup were completed—reducing downtime and keeping teams focused on customers in line with their Customer Focused core value.
Simulation-driven confidence with Twin IQ: inVia’s Twin IQ helped model and test workflows in advance, helping them make faster, smarter decisions and continuously improve after deployment.
“inVia’s team worked at lightning speed—scoping, developing, and launching enhancements in days, not months. Their agility gave us the confidence to roll out fast without disrupting our operations.“
– Michael Huffaker, COO, CarParts.com
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