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A optometry lab
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The Brief

Our client, a leading global optical supplier, has worked with us for many years and approached us to support a central sustainability and digital transformation project within their UK lab. Their goal: to streamline production, reduce waste, and create an efficient, traceable workflow from lens pairing through to despatch - without disrupting day-to-day operations.

The existing process relied heavily on manual steps and paper-based tracking, with several disconnected apps leading to login issues and inefficiencies across teams. Our challenge was to unify and automate the process, reduce paper usage, and give the business better visibility of every order moving through the lab.

Trays on conveyor Old trays

Previously

  • Trays were labelled manually with printed paper barcodes.
  • Staff paired lenses with frames by scanning each item individually using three separate legacy apps.
  • Frequent log-in issues and app switching slowed productivity.
  • QA teams inspected and fitted lenses to frames on a conveyor belt with no way to document condition or trace where damage occurred.
  • Orders were grouped manually by location for dispatch.
  • Customer damage claims were complex to verify due to a lack of traceability.

Our Solution

We designed and delivered a custom-built unified application that transformed the workflow connecting hardware, software, and data in real time.

  • Unified App

    A bespoke Vue-based app (powered by a Laravel API) integrates tray assignment, lens-frame pairing, QA checks, and despatch scanning — all from one interface.

  • Digital Trays

    Electronic shelf labels (ESLs) replaced paper barcodes, enabling trays to be digitally tracked and labels to be automatically cleared for reuse.

  • integrated QA process

    The QA team can now capture high-quality images and video of each lens-frame pairing, stored directly in the app. This provides a visual record of every order for training, quality assurance, and claim validation.

  • End-to-End Automation

    Data flows through the system in real time, from the conveyor belt to despatch. Orders are automatically routed to the correct stage via integration with the conveyor control host - eliminating manual sorting and saving valuable man-hours.

  • Reporting & Dashboards

    A live dashboard displays lab activity — tracking orders, reporting progress, and visualising workflow status. Once opened, it self-updates automatically.

  • Sustainability Wins

    The move to digital labels removed the need to print over 300,000 paper dockets annually.

Desktop Wireframes

  1. Desktop app wireframe 1
  2. Desktop app wireframe 2

App Wireframes

  1. Mobile app wireframe 1
  2. Mobile app wireframe 2
  3. Mobile app wireframe 3
  4. Mobile app wireframe 4

Technical Stack
& Integrations

This project combined several complex systems into a single, automated digital ecosystem.

  • Frontend

    Vue.js application built to integrate seamlessly with Zebra barcode scanners.

  • Backend

    Laravel API managing all app logic, feeds, and integrations.

  • Data Imports

    CSV data from multiple systems consolidated into one environment.

  • Hosting & Connectivity

    Secure VPN tunnel to connect with Monk hosting.

  • ESL Integration

    Solum electronic labels drive real-time tray updates.

  • Printing Backup

    Offline printing fallback for downtime resilience.

  • DX REST API

    Integrated for automated delivery label generation.

  • Customs Integration

    Automated handling for Channel Islands and Northern Ireland shipments (Windsor Framework compliance).

  • SAP Integration

    Real-time tracking number updates pushed directly to SAP.

The Outcome

This project is a great example of what happens when automation, data, and sustainability come together. What began as a sustainability challenge turned into a complete digital transformation - connecting systems, simplifying workflows, and saving time, paper, and frustration.

For this client, the result wasn't just a more efficient lab - it was a more innovative, greener way of working.

Results

  • 300,000+ fewer paper dockets printed annually - a significant step toward the client's sustainability goals.
  • Complete traceability - every order now has a visual and digital audit trail from start to finish.
  • Faster processing - automation across the conveyor and despatch process has saved significant manual labour hours.
  • Reduced customer complaints - improved QA and full visibility over damage or defect handling.
  • Happier teams - no more app switching, login issues, or duplicate data entry.
Carl Zeiss app screenshot Carl Zeiss app screenshot
Jon Lebbon

The team at Kaweb constantly go above and beyond. The management team have built a great dev team who are always on hand to support. They explain solutions in plain English so you don’t get wrapped up in jargon.

We have been collaborating with them for about 13 years and have lost count of the number of new features and tools we have embedded thanks to Kaweb. I have always been pleased with the developments they deliver & the support they provide. Definitely couldn’t ask for more.

Jonathan Lebbon
Applications Service Owner, Carl Zeiss