AI-Driven Trip Creation for High-Throughput Deliveries

A leading retailer partnered with INTECH to replace manual trip planning with an AI-powered Auto Trip Creation System automating clustering, routing, and load balancing. Within weeks, dispatch accelerated, vehicle utilization improved, and a scalable last-mile engine supported growth.

Client Overview

A National Retailer Scaling High-Velocity Last-Mile Operations

  • Client

    One of India's largest home essentials retailers with a nationwide network of fulfillment centers and delivery points

  • Industry

    Large-format retail and omnichannel e-commerce with high-volume last-mile logistics

  • Core Offering

    Value-led home essentials delivered on tight schedules; customer experience anchored in reliable, time-bound service

  • Mandate

    Replace manual trip planning with intelligent automation to improve route efficiency, maximize capacity, and scale reliably through seasonal spikes while protecting brand promise and margins

Challenges We Overcome

Operational Bottlenecks Limiting Last-Mile Scale

Manual Trip Planning

Dispatchers clustered shipments and assigned vehicles by hand across multiple FCs, delaying departures, inflating overtime, and leaving no resilience for rapid replans or exceptions

Inefficient, Inconsistent Routing

Without algorithmic guidance, drivers doubled back, hit congestion, and revisited zones missing time windows, raising fuel spend, and depressing daily throughput

Underutilized Fleet Capacity

Lack of automated load balancing sent trucks out partially filled. Extra runs, empty miles, and uneven utilization spiked cost per order

Fragile Peak Handling

Sales and festive surges overwhelmed manual coordination, breaking handoffs between FCs and last-mile teams, triggering bottlenecks, failed scans, and missed cutoffs

Limited Visibility & Slow Decisions

Siloed lists and offline tools masked ETA risk and capacity headroom, preventing timely re-sequencing, load splits, or shift adds

Constrained Expansion

Operational fragility stalled entry into new zones; scaling required disproportionate headcount and risk, undermining SLAs and growth timelines

Solutions

INTECH's AI Trip Creation: Intelligent Last-Mile Orchestration at Scale

AI Clustering Engine

Groups shipments by proximity, time windows, and fulfillment mode to form dense, logical trips that minimize zigzags and prep cleaner inputs for routing

Dynamic Route Optimization

Continuously re-sequences stops with live traffic, cutoff times, and hub constraints to cut miles per drop and missed windows

Dual-Mode Handling (Home & Pickup)

Unifies home delivery and pickup point flows in a single plan, removing manual splits and preserving SLAs

Load Balancing Algorithm

Maximizes vehicle fill to consistently achieve 25–30 deliveries per trip, reducing runs and cost per order

Real-Time Processing at Scale

Streams orders and statuses for near real-time grouping and assignment, enabling rapid replans during peaks

Tech Stack

The AI Infrastructure Behind High-Throughput Trip Planning

Python (ML & Optimization Engine)

Builds clustering, routing, and load-balancing logic tailored to geography, windows, and capacity; rapid iteration delivers dense trips and consistent 25–30 drops per route

Flask (Microservices Layer)

Stateless APIs for create/replan/assign keep dispatch responsive; horizontal scaling and isolation improve resilience at peak load

REST Integrations (OMS/WMS & Driver Apps)

Bi-directional data flows for orders, capacity, status, and POD enable seamless handoffs across fulfillment and last mile

Apache Kafka (Streaming & Orchestration)

Real-time events for orders, locations, and exceptions power live re-sequencing, retries, and back-pressure handling during spikes

Results

AI-Powered Logistics That Scales with Every Shipment

Planning time cut to minutes

Automated clustering and routing accelerated dispatch readiness and stabilized departure cutoffs across zones

25–30 deliveries per trip achieved

Load balancing improved vehicle utilization, reduced empty miles, and lowered cost per order

Higher on-time performance

Dynamic re-sequencing against traffic and service windows shortened ETAs and reduced reattempts

Cost efficiency at scale

Better packing density and fewer extra runs decreased fuel spend and operational overhead

Peak resilience proven

Event-driven replans maintained throughput during sales spikes and festive surges without schedule chaos

Control-tower visibility

Real-time dashboards surfaced exceptions and capacity headroom, enabling faster interventions and continuous improvement

Business Benefits

From Reactive Dispatch to Proactive Last-Mile Intelligence

  • Transparent operations

    Live capacity, ETA, and exception views enabled faster interventions and steadier cutoffs

  • Reduced delivery cost

    Higher vehicle fill and fewer empty miles lowered runs, fuel, and overtime

  • Faster decisions

    Real-time dashboards replaced manual planning, accelerating replans and zone balancing

  • Stronger on-time SLAs

    Dynamic re-sequencing cut missed windows and shortened ETAs

  • Governance & control

    Standardized workflows and audit-ready logs aligned teams and reduced variance

  • Scalable growth

    API-first design added zones and modes without proportional headcount

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