Gap and Old Navy distribution centers needed reliable automation without the scale that justified a full orchestration layer. They required dependable PLC integration and upstream communication to WMS for orders, statuses, and inventory routing.

We deployed a single instance of our proven warehouse services stack per site, simplifying operations while retaining robust messaging and PLC control. The solution handled routing decisions locally and synchronized with WMS so inventory and order status stayed accurate without overcomplicating the architecture.

Service Stack

• C#/.NET Framework services hosted on IIS with Oracle DB for persistence and MongoDB for cached workflow instances in case of failures.
• Neuron ESB for pub/sub messaging between services and PLC integrations.

Integrations

• PLC communication for conveyor routing and equipment commands.
• Upstream messaging to WMS for order updates, inventory status, and exception handling.

• Single-stack deployment per warehouse to reduce complexity.
• PLC-connected routing with pub/sub messaging.
• Real-time communication to WMS for orders and statuses.
• Database-backed audit trails for movements and exceptions.

The DCs achieved reliable automation without the overhead of a multi-zone orchestration layer. Ops teams had a straightforward, supportable stack while still meeting throughput and accuracy goals for order fulfillment.