Case Study
How Leggero reduced inventory by 40%, improved production flow, and streamlined order management with Wheelhouse
Estimated Annual CSR Labor Savings
Inventory Reduction
Annual Paper & Printing Savings
Dealer Orders Now Placed After Hours
Leggero manufactures pediatric mobility devices — including specialized strollers and wheelchairs — for children with complex medical needs. Their products require careful configuration, detailed documentation, and tightly coordinated production workflows. As demand grew, Leggero needed a more reliable, connected system to manage quoting, ordering, production, inventory, and compliance.
Leggero relied on spreadsheets, manual processes, and paper-heavy workflows for order entry, production documentation, and regulatory labeling. These processes slowed their team, created unnecessary administrative burden, and made real-time visibility difficult.
Key challenges included:
• $1,000+ monthly costs for printing, ink, and paper (20 pages per order)
• Manual Kanban tracking in spreadsheets causing data capture errors
• Limited visibility into production and inventory status
• Complex regulatory requirements for FDA UDI (unique device identifier) labeling
• Dealers unable to place orders after hours, creating next-day email backlogs
• Manually generated commission reports for manufacturer's rep network
• Heavy administrative load on customer service agents due to manual workflows
Leggero needed a connected system that streamlined operations end-to-end — without requiring a large administrative staff.
Leggero partnered with Wheelhouse to modernize their operation, combining the platform’s built-in capabilities with targeted professional services support from the Wheelhouse team.
Key improvements included:
• Digitized production workflows supported by QR-code scanning
• Integrated Kanban inventory system with QR-triggered replenishment
• Automatic purchasing queue based on Kanban scans and ideal stock thresholds
• Vendor ordering aligned to actual consumption, enabling leaner inventory
• Dealer & rep self-service ordering, reducing CSR workload
• Automated, accurate commission reporting for reps and managers
• Model-level reporting, allowing Leggero to group product models and analyze performance
• Automated FDA UDI labeling with built-in serialization, generating unique serial numbers for each unit
• Centralized, role-based access for operators, CSRs, reps, and managers
• Rule-based configuration checks that prevent invalid builds and reduce rework
• Real-time visibility into inventory levels, order stages, and production progress
Leggero now maintains and expands much of their workflow inside Wheelhouse, supported by as-needed professional services and collaboration with the Wheelhouse team.
THE RESULTS
$100K
Estimated Annual CSR Labor Savings
Leggero avoided hiring multiple additional CSRs by streamlining order entry, automating workflows, and enabling dealer self-service.
40%
Inventory Reduction
QR-based Kanban ensures inventory matches consumption, reducing carrying costs and improving space utilization.
$12K+
Annual Paper & Printing Savings
Digitized workflows significantly reduced the need for printed instructions and documentation.
20%
Dealer Orders Now Placed After Hours
Self-service ordering improved responsiveness and reduced next-day backlog.
Zero Configuration Errors Reach Production
Built-in compatibility rules catch issues before they disrupt manufacturing.
Real-Time Visibility & Faster Reporting
Teams can instantly see inventory levels, order status, and model-level performance.
More Efficient Sales Network Management
Reps and the National Sales Manager now access customer, territory, and commission data without manual report generation.
ADDITIONAL OUTCOMES
Operational Visibility
Live tracking of work-in-process and inventory levels.
Quality Control
Configuration rules prevent invalid combinations before they hit the floor.
Compliance Automation
UDI serialization and labeling are automated and consistent.
Lean Purchasing
Kanban triggers streamline purchasing and reduce administrative work.
Sales Network Enablement
Reps operate on current data instead of relying on emailed spreadsheets.
"With the configurator that we’re using now, there’s pretty much zero room for error. If we’re creating a quote and something is out of stock or not compatible, Wheelhouse catches it before it becomes a problem."
Josh T.
National Sales Manager, Leggero
"Wheelhouse transformed the way our entire operation runs. Our teams can see exactly what’s happening in real time — orders, inventory, production steps, everything. It has reduced so much manual work and helped us operate far more efficiently than before."
Ornan C.
Operations Manager, Leggero
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